90 91ecb

BACKUP G R O U P I N D E X &ma
;r Service Manual Introduction and

Master Troubleshooting . . . . . .,. . . . . . . . . r.. m
LASER
,
Lubrication and Maintenance . . . . . . . . ‘- ‘8
0
TALON
; “. i ,
.Front Suspension . . . . . . . . . . . . . . ..*............d...
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..‘....................

. /
1991 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes-Parking
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~......................‘t.
Volume-l
Engine, Chassis Cooling . . . . . . . . . . . . . . . . . ..i....................................
& Body ,., .‘, -,
Engine ..i....~....r...............~....~.*,.~.~.~,‘~~...;..~~..
Intake and Exhaust . . . . . . ..L....................

FOREWORD
This Service Manual has been prepared with the Fuel System . . . . . . . . . . . ..ti.......r................~...
latest service information available at the time of
‘* publication. It is subdivided into various group
categories and each section contains diagnosis, Propeller Shaft ....................................... I
disassembly, repair, and installation procedures
along with complete specifications and tightening ......................... . . ..y.f...
R e a r Suspensiori
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or Manual
restore the high levels of performance and reliability Steering- Power .....................................
designed into these outstanding vehicles.
Manual I
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE transaxle-Automatic .............:;i...,; .... .;
WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWN
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original
manual was lost or destroyed.)
Please See README.N or README.HTML for additional information

Wheels and Tires .................................
Thank you. G~mm~emymanual@hotma~l.com
Body .............................................................
1,
wA Heater & Air Conditioning ..............
CHRYSLER Emission Contr6l Systems ..............

CORPORATION
I
Chrysler Corporation reserves the right to make changes in design 0’: to
make additions to or improvements in its products without lmqoslng NOTE: For Electrical, refer to
d ., . any obligations upon itself to install them on its products previously Volume-2 “Electrical”.
manufactured.
0 1990 Mitsubishi Motors Corporation Printed in U.S.A.

2 INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual
HOW TO USE THIS MANUAL NOaM
CONTENTS LIMIT -9
The preceding page contains GROUP INDEX which Shows the standard for judging the quality of a part -
lists the group title and group number. or assembly on inspection and,means the maximum
or minimum value within which the part or assembly
PAGE NUMBERS
must be kept functionally or in strength. It is a value
All page numbers consist of two sets of digits
established outside the range of standard value.
separated by a dash. The digits preceding the dash
identify the number of the group. The digits follow-
ing the dash represent the consecutive page num-
ber within the group. The page numbers can be
found on the top left or right of each page.
TEXT
Unless otherwise specified, each service procedure
covers all models. Procedures covering specific
models are identified by the model codes, or similar
designation (engine type, transaxle type, etc.). A Removal steps : The numbers before part
description of these designations is covered in this name correspond to numbers
unit under “VEHICLE IDENTIFICATION”. in the illustration, and indicate
the order of removal.
TROUBLESHOOTING Disassembly steps : The numbers before part
name correspond to num-
Troubleshootings are classified into master trouble- bers in the illustration,
shooting and group troubleshooting and located as and indicate the order of
disassembly.
follows: Installation steps : This is provided if installa-
The master troubleshooting is prepared when the tion cannot’be made in the
trouble symptom relates to two or more groups and reverse order of “Removal
steps “; omitted if installa-
given in MASTER TROUBLESHOOTING. tion in the reverse order of
The group troubleshooting guide is prepared for “Removal steps” k possi- rL+
causes of problems related to that individual group ble. . .
only; a troubleshooting guide is prepared for each Reassembly steps : This is .provided if reas-
sembly cannot be made
appropriate group. in the reverse order of
“Disassembly steps” ;
SERVICE PROCEDURES omitted if reassembly in
The service steps are arranged in numerical order the reverse order of “Dis-
assembly steps” is possi-
and attentions to be paid in performing vehicle ble.
service are described in detail in SERVICE POINTS.
DEFINITION OF TERMS
STANDARD VALUE .IVL , -....-
ce : Removal
Indicates the value used as the standard for judging l 4 : Installation
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T : Indicates the manual transaxle, or models equipped with the manual transaxle.
A/T: Indicates the automatic transaxle, or models equipped with the automatic transaxle.
MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.
SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an
engine.
DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an
engine.
Turbo: Indicates an engine with turbocharger, or a model equipped with such an engine.
Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine.
FWD: Indicates the front wheel drive vehicles.
AWD: Indicates the all wheel drive vehicles.
ABS: Indicates the anti-lock braking system or models equipped with the anti-lock braking system.
INTRODUCTION AND MASTER TROUBLESHOOTING - How to Use This Manual 3
Indicates the incidental operation to be

performed before removal or after installa-
Page number Group title
I
524 4
BRAKES-Roar Brake Wlmd Cylinder
4
REAR BRAKE WHEEL CYLINDER
3ENjOVAL AND lNSTAU.AllON
I I
-
Remwal stepa
1. Brake drum
2. Bleeder screw
3. Brake tube connection NOTE
l * 4. Wheel cylinder assembly I1 l Reverse the removal procedures to reinstall.
l e 5. Wheel cylinder boot 12) M : Refer to ‘Service Points of Aemcval”.
l + 6. Piston assembly (3) l * : Refer to ‘Service Points of Installation’.
- n** 7. Piston cue 14) q :Nc+-r-reusab(epatts
SERWE POINTS REMOVAL’
-7. REMOVAL OF PISTON CUP
Using a screwdriver, remove the piston cup from the piston.
INSPECTION -
Check the following points. and if there is any abnormality, replace
the entire wheel cylinder assembly.
(1) Check piston and wheel cylinder walls for rust or damage.
(2) Check clearance between the cylinder and the piston.
Measure in two perpendicular directions to figure the clear-
ance between the wheel cylinder inner diameter fmax.value)
and the piston outer diameter (minvalue).
Limit : 0.15 mm (4059 in.)
NOTE
If the difference is more than the limit, replace the piston and
wheel cylinder as an assembly.
This number corresponds to

the number in “Removal
steps”, “Disassembly
steps”, “Installation steps”
or “Reassembly steps”.
4 INTRODUCTION AND MASTER TROUBLESHOOTING - How to use This Manual
EXPLANATION OF THE TROUBLESHOOTING GUIDE
rIndicates
3. Checking the passenger compartment-temperature sensor, outside-air sensor, air-
thermostat sensor and refrigerant-temperature sensor circuits
the
circuit diagram
for checking
(including the
I I* interface of the
air conditioner
control unit).
in the opera-
tion descrip-
Provides the
scription of cir- l1 tions only as

necessary, and
these numbers
correspond to
I--
Operation description the numbers
cuit operation A negative-characterlstlc thermstor 1s employed for each sensor in order 10 convey the amblent
for basic under- temperature of the sensor pan ,o resistance used in har-
The sensor power-supply I2 5V) of the awcondltww ““I, IS applied to the
standing. lermlnals 116). (15). (17) (5) dlvlded res~~,ance ness and com-
reSlSta”ce R
ponent layout
Tmublrhooting 4 I diaarams.
Dlagnosls
N o 1 2 T h e ou,s,de-a,, sensor ,nput slgnal IS h e l d to 15°C 159°F)

N o 1 3 T h e air-thermostat tensor ~np”t slgnal IS h e l d 10 4°C 139°F)
Terminal CO”dl,,O”* Terminal voltage Provides hints

I NO I S’g”a’ I (including
1 judgement)
when trouble-
cedures are fol-

lowed.
Indicates the
diagnosis out-
put code No.
and the system
conditions dur-
kng o u t p u t .
the Indicates the specification to

conditions un- be used for judgement of
der which the the check results.
If there is no particular men-
be made. tion of conditions in the
“Conditions” column, the
column shows the specifica-
tion under normal condi-
tions.
INTRODUCTION AND MASTER TROUBLESHOOTING - ‘How to use miS .Manual 5
EXPLANATION OF CIRCUIT DIAGRAMS

-I The symbols used in circuit diagrams are used as NOTE
described below. For detailed information cqncqning the reading of
circuit diagrams, refer to GROUP 8-Wi@ng Har-
ness.
The input/output (dire%%

Indicates a of current flow) relative to
connector. the electronic control unit
is indicated by symbols
(A.m.
The (A) symbol indicates
that current flows in the
upward direction.
Output
Input .A Input/output
IGNITION
SWITCH(IG1)
The connector
symbol indicates
the device side reht flow is indicat- :
connector (for an ed by the arrow.
intermediate con- In this instance, the
nector, the male current flow is in
side connector) both directions, up
as seen from the c
\
terminal front
(the connector’s
connection face).
I
Indicates Indicates the
device side con- that the con- branch point of a
nector is the harness of a differ-
direct-inser- ent line diameter
tion type. nr line colour. I
6 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identificetion
VEHICLE IDENTIFICATION Nmx-

VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (V.I.N.) is located oh a plate
attached to the left top side of the instrument panel.
VEHICLE IDENTIFICATION CODE CHART PLA.4

All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
rr
\
12th to
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th
17th
Digit Digit Digit Digit Digit Digit Digit Digit Digit Digit Digit Digits
Vehicle Price *Check Model Serial

Country Make Others Line Body Engine Plant
We class year number
4- E- 3- B- S- 3- 4- T- M- E- 000001
USA Eagle Passen- Manual Laser or Medium 3 door 1.8 liter 1991 DSM to
P- ger Car Seat Belt Talon 4- Hatch- (107 Year 999999
Plymouth c- FWD High back cu.in.)
Auto- T- 5- [SOHC-
matic Talon Premium MPI1
Seat Belt AWD 6- R-
Special 2.0 liters
(122
cu.in.)
[DOHC-
MPI]
u-
2.0 liters
(122
I
cuin.)
[DOHC-
MPI-
Turbo]
NOTE * “Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification number.
INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
VEHICLE IDENTIFICATION NUMBER LIST NOOCC--

p, VEHICLES FOR FEDERAL
,.. I
V.I.N. (except sequence number) Brand Engine Displacement Models Code

,,; * /./
4P3CS34aM E Plymouth Laser 1.8 liter (107 cuin.) D21AMNJElXP/RJEL4P’
[SOHC-MPI]
4P3CS44aME D21AMNHEL4P/RHEL4P
4P3CS44ROME 2.0 liter (122 cuin.) D22AMNHML4P/RHML4P
[DOHC-MPI]
4P3CS44UuME 2.0 liter (122 cu.in.) D22AMNHFL4P/RHFL4P
[DOHC-MPI-Turbo]
4E3CS44ROM E Eap$DTrlon 2.0 liter (122 cu.in.) D22AMNHML4EIRHML4E

[DOHC-MPI]
4E3CS54UnME 2.0 liter (122 cu.in.) D22AMNPFL4EIRPFL4E
[DOHC-MPI-Turbo]
4E3CT64UOME Eagle Talon D27AMNGFL4E/kGFL4E
<AWD> .1 L *,
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number) Brand Engine Displacement Models Code
4P3CS34aME Plymouth Laser 1.8 liter (107 cu.in.) D21AMNJELSP/RJELSP

[SOHC-MPI]
4P3CS44aME D21AMNHELSP/RHELSP
4P3CS44RmME 2.0 liter (122 cuin.) D22AMNHMLSP/RHMLSP

[DOHC-MPI]
4P3CS44UOME 2.0 liter (122 cu.in.1 D22AMNHFLSP/RHFLSP

[DOHC-MPI-Turbo] ‘.
4E3CS44RuME Eagle Talon 2.0 liter (122 cu.in.1 D22AMNHMLSE/RHMLSE
<FWD> [DOHC-MPI]
4E3CS54UOME 2.0 liter (122 cu.in.1 D22AMNPFLSElRPFLSE

[DOHC-MPI-Turbo]
4E3CT64UOME Eagle Talon D27AMNGFLSE/RGFLSE
<AWD>
VEHICLES FOR CANADA
V.I.N. (except sequence number) Brand Engine Displacement Models Code 1’ 1

4P3BS34aME Plymouth Laser 1.8 liter (107 cu.in.1 D21AMNJEL5P/RJEL5P
[SOHC-MPI]
4P3BS44aME D21AMNHiL5P/RHEL5P
4P3BS44ROME 2.0 liter (122 cuin.) D22AMNHML5P/RHML5P
[DOHC-MPI]
4P3BS44UuME 2.0 liter (122 cu.in.) D22AMNHFL5P/RHFL5P
[DOHC-MPI-Turbo]
4E3BS44ROME Eagle Talon 2.0 liter (122 cu.in.) D22AMNHML5EiRHML5E
<FWD> [DOHC-MPI] I I
4E3BS54UuME 2.0 liter (122 cu.in.1
[DOHC-MPI-Turbo]
4E3BT64UnME Eagle Talon
<AWD>
8 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
VEHICLE INFORMATION CODE PLATE NOOCD-
Vehicle information code plate is riveted onto the bulkhead in ri

the engine compartment.
The plate shows model code, engine model, transaxle model,
and body color code.
1. MODEL D22AMN HML4P
2 y$y:/e ‘f$$l
2. ENGINE 4G63
IEngine model
3. TRANSAXLE F5M33
yTransaxle model
4. COLOR, B14
TRIM OPT I Monotone exterior
color code
VEHICLE SAFETY CERTIFICATION LABEL NOOCF-
1. The vehicle safety certification label is attached to the face
2. This label indicates the month and year of manufacture, ;e

Gross Vehicle Weight Rating (G.V.W.R.), Gross Axle
(G.A.W.R.) front and rear, and Vehicle
Identification Number (V.I.N.).
ENGINE MODEL STAMPING NOOCG-
1. The engine model number is stamped at the front side on
following:
Engine model Engine displacement

4637 1.8 liter (107 cu.in.)
[SOHC-MPI]
4G63 2.0 liter (122 cuin.)
[DOHC-MPI] or [DOHC-MPI-Turbo]
2. The engine serial number is stamped near the engine

model number, and the serial number cycles, as shown
below.
Engine serial number Number cycling ‘-w
AA0201 t o w9999 AA0201 - - - - - - - -*AA99997
I 1 LAB0001 - - - - - - - +AY9999 : 1
I 1 t-BAOOOI - - - - - - - +YY9999 ’ 1
INTRODUCTlON AND MASTER TROUBLESHOOTING - Vehicle Identification 9
Theft protection label THEFT PROTECTION NowlAB

onginal parts
In order to protect against theft, a Vehicle Identification
Number WIN) is stamped in, or attached as a label to, the
w ,I e IW following major parts of the engine and transaxle, as tiell as
main outer panels:
B ,w w
Engine cylinder block, Transaxle housing, Fender, Door, Quar-
OOA0212 ter panel, Hood, Trunk lid, Bumpers
For replacement parts

In addition, a theft-protection label is attached to replacement
parts for the body outer panel main components, and the same
data are stamped into replacement parts for the engine and the
transaxle.
Cautions regarding panel repairs

1. When repainting original parts, do so after first mask-
OOA0213 ing the theft-protection label, and, after painting, be
sure to peel off the masking tape.
2. The theft-protection label for replacement parts is
covered by masking tape, so such parts can be painted
as is. The masking tape should be removed after
painting is finished.
3. The theft-protection label should not be removed from
original parts or replacement parts.
LOCATIONS
OOA0057 OOA0055
IO INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
Part
Transaxle Manual transaxle Automatic transaxle
Fender
The illustration indicates left hand side, outer. 3lA0259
Door
- .
31AO250
INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification 11
: for original equipment parts

Part Target area : for replacement parts
Quarter panel The label is attached at the
inner side of the parts showr
in the figure.
The illustration indicates left hand side, outer.

Right hand side is symmetrically opposite. 31A026E
Hood The label is attached at the

inner side of the parts shown
in the figure.
31A0256
Tailgate The label is attached at the

inner side of the parts shown
in the figure.
31AO260
12 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
m : for original equipment parts

Part Target area m : for replacement parts
Front bumper
The label is attached at the inner side of the parts shown in the figure. 31A0332
Rear bumper
The label is attached at the inner side of the parts shown in the figure. 31A0332
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions befdre Service ‘1 S
PRECAUTIONS BEFORE SERVICE wxww

PROTECTING THE VEHICLE
If there is a likelihood of damaging painted or interior parts
during service operations, protect them with suitable covers
(such as seat covers, fender covers, etc.).
REMOVAL AND DISASSEMBLY

When checking a malfunction, find the cause of the problem. If
it is determined that removal and/or disassembly is necessary,
perform the work by following the procedures contained in this
Service Manual.
If punch marks or mating marks are made to avoid error in

assembly and to facilitate the assembly work, be sure’to make
them in locations which will have no detrimental effect on
performance and/or appearances.
OOV663 If an area having many parts, similar parts, and/or parts which
are symmetrical right and left is disassembled; be sure to
arrange the parts so that they do not become mixed during the
assembly process.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.
i:c ” -,.
> ‘.
.“i,. i
J
” , ‘. 5,
OOY192 FOOO 1. 7
SPECIAL TOOLS
If other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the technician might be injured; therefore, be sure
to use the special tool whenever doing any work for which the
use of one is specified.
FOOO18
PARTS TO BE REPLACED
If any of the following parts are removed, they must be
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
0
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
OOD511
I4 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service
PARTS
When replacing parts, use MOPAR genuine parts.
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (12 in.) from any
plastic parts and all opening parts (doors, luggage compart-
ment, etc.).
mm (In.1 smo59
SERVICING ELECTRICAL SYSTEM

1. Note the following before proceeding with work on the
electrical system.
Note that the following must never be done:
Unauthorized modifications of any electrical device or
wiring, because such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result
in a fire in the vehicle.
2. When servicing the electrical system, disconnect the
negative cable terminal from the batten/.
Caution
1. Before connecting or disconnecting the negative
cable, be sure to turn off the ignition switch and the
lighting switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
2. For MPI-equipped models, after completion of the
work steps [when the battery’s negative (-) termi-
nal is connected], warm up the engine and allow it
to idle for approximately five minutes under the
conditions described below, in order to stabilize
engine control conditions, and then check to be
sure that the idling is satisfactory.
Engine coolant temperature: 85-95°C (185-203°F)
Lights, electric fans, accessories: OFF
Transaxle: neutral position
(A/T models: “N” or “P”)
Steering wheel: neutral (center) position
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Set&e 15
WIRING HARNESSES
1. Secure the wiring harnesses by using cla’mps. However, for
any harness which passes to the engine or other vibrating
parts of the vehicle, allow some slack within a range that
does not allow the engine vibrations to cause the harness
to come into contact with any of the surrounding parts.
Then secure the harness by using a clamp.
In addition, if a mounting indication mark (yellow tape) is on
a harness, secure the indication mark in the specified
location.
2. If any section of a wiring harness contacts the edge of a

part, or a corner, wrap the section of the harness with tape
or something similar in order to protect it from damage.
F16171
Correct 3. When disconnecting a connector, be sure to pull only the

connector, not the harness.
4. Disconnect connectors which have catches by pressing in

the direction indicated by the arrows in the illustration.
Cl6385
Cl6367
Y16347
16 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service
5. Connect connectors which have catches by inserting the

connectors until they snap.
9%
ELECTRICAL COMPONENTS
1. When installing any of the vehicle parts, be careful not to
pinch or damage any of the wiring harnesses.
Cl6362
2. Sensors, relays, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped or
mishandled.
,**
OOYSss
3. The electronic parts used for relays, etc., are sensitive to

heat. If any service which causes a temperature of 80°C
(176°F) or more is performed, remove the part or parts in
question before carrying out the service.
FUSES AND FUSIBLE LINKS

OOV833
1. If a blown-out fuse is to be replaced, be sure to use only a
fuse of the specified capacity. If a fuse of a capacity larger
than that specified is used, parts may be damaged and the
circuit may not be protected adequately.
Caution
1. If a fuse is blown-out, be sure to eliminate the cause
of the problem before installing a new fuse. ;i
2. Check the condition of fuse holders. If rust or dirt is
found, clean metal parts with a fine-grained sand-
paper until proper metal-to-metal contact is made.
10A 15A Poor contact of any fuse holder will often lead to
voltage drop or heating in the circuit and colild
COY569 result in improper circuit operation.
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Sew&e ‘37
Permissible current
2. If additional optional equipment is to be installed, in ttie
Nominal SAE vehicle, follow the procedure listed in the ap@@priate
r ‘.
size In engine Other instruction manual; however, be sure to pay “careful
gi:e compart- areas
attention to the following points: “9:
ment
(1) In order to avoid overloading the wiring;’ take the
0.3 mm2 AWG 22 - 5A electrical current load of the optional ,equipment into
0.5 mm2 AWG 20 7A 13A consideration, and determine the appropriate .wire size:
0.85 mm’ AWG 18 9A 17A (2) Where possible, route the wiring through the existing
1.25 mm2 AWG 16 12A 22A harnesses.
2.0 mm2 AWG 14 16A 30A (3) If an ammeter or similar instrument is to be connected
3.0 mm’ AWG 12 21A 40A to a live-wire circuit, use tape to protect the wire, use a
5.0 mm2 AWG 10 31A 54A clamp to secure the wire, and make sure that there is
no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any gasoline, oil, etc., or rubber
parts, they might be adversely affected.
oorsas
LUBRICANTS
In accordance with the instructions in this Service Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
!’
>,IIV/ :
BRAKE FLUID
Be careful to avoid spilling any brake fluid on painted surfaces,
because the paint coat might be discolored or damaged.
18 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions b&ire Service
DOING SERVICE WORK IN GROUPS OF VO’bR

MORE TECHNICIANS .-
I-7. I
If the service work is to be done by two or more technicians
working together, extra caution must be taken.
NOTE ON INSTALLATION OF RADIO EQIJIPMEATe

The computers of the electronic control system has been
designed so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver etc. is
routed near the computers, it may affect the operation of the
computers, even if the output of the transceiver is no more
than 25W.
To protect each of the computers from interference by
transmitter (hum, transceiver, etc.), the following should be
observed.
1. Install the antenna on the roof or rear bumper.
2. Because radio waves are emitted from the coaxial cable of
the antenna, keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross h
the wiring harness, route it so that it runs at right angles to
the wiring harness.
3. The antenna and the cable should be well matched, and the
standing-wave ratio* should be kept low.
4. A transmitter having a large output should not be installed
in the vehicle.
5. After installation of transmitter, run the engine at idle, emit
radio waves from the transmitter and make sure that the
engine is not affected.
Voltage Maximum
distribution voltage “STANDING-WAVE RATIO
If an antenna and a cable having different impedances are
connected, the input impedance Zi will vary in accordance with
the length of the cable and the frequency of the transmitter,
and the voltage distribution will also vary in accordance with
the location.
The ratio between this maximum voltage and minimum voltage
is called the standing-wave ratio. It can also be represented by
the ratio between the impedances of the antenna and the
cable.
The amount of radio waves emitted from the cable increases
as the standing-wave ratio increases, and this increases the
possibility of the electronic components being adversely
affected.
INTRODUCTION AND MASTER TROUBLESHOOTtNG - Towing and Hoi&g T9
I-
Sling type
TOWING AND HOISTING NOOGA-
c
llJ/RE;~R TOWING RECOMMENDATION
FRONT TOWING PICKUP

Caution
This vehicle cannot be towed by a wrecker using sling-type
Wheel lift type equipment to prevent the bumper from deformation.
If this vehicle is towed, use wheel lift or flat bed
equipment.
The vehicle may be towed on its rear wheels for extended
distances provided the parking brake is released. It is recom-
mended that vehicles be towed using the front pickup
whenever possible.
Flat bed type
REAR TOWING PICKUP

iling type
Caution
This vehicle cannot be towed by a wrecker using sling-type
--
equipment to prevent the axle beam from deformation.
lf this vehicle is towed, use wheel lift or flat bed
equipment.
Manual transaxle vehicles may be towed on the front wheels,
Vheel lift type provided the transaxle is in neutral and the drive-line has not
been damaged. The steering wheel must be clam,ped in the
straight-ahead position with a steering wheel clamping device
designed for towing service use.
Caution
Do not use steering column lock to secure front wheel
position for towing. 3,“’
lat bed type Automatic transaxle vehicle may be towed on the frontwheels
at speeds not to exceed 50 km/h (30 mph) for a distances hot
to exceed 30 km (18 miles).
Caution
If these limits cannot be met, the front wheels must ‘be
placed on a tow dolly.
TOWING WHEN KEYS ARE NOT AVAILABLE

When a locked vehicle must be towed and keys are not
available, the vehicle may be lifted and towed from the front,,
provided the parking brake is released: If not released, the rear
wheels should be placed on a tow dolly.
I
20 INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting
SAFETY PRECAUTIONS
The following precautions should be taken when towin the
vehicle.
1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO
OR WRAPPING AROUND THE BUMPER.
2. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior to
moving the vehicle.
3. Operator should refrain from going under a vehicle while it
is lifted by the towing equipment, unless the vehicle in
adequately supported by satefy stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed
when towing a vehicle.
<AWD>
Refer to the section “Special Handling Instructions for AWD
Models”.
HOISTING
Frame contact support location
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations.
Caution
OOAOI 71
When service procedures require removing rear sutpen-
sion, fuel tank, spare tire and lift gate, place addmonal
<FWD>: 928mm (36.5 in.) weight on rear end of vehicle or anchor vehicle to hoist to
<AWD>: 998mm (39.3 in.)
prevent tipping of center of gravity changes.
FLOOR JACK
The usual type of floor jack is used at the following locations.
Front:
<FWD> Under the mid point of centermember
<AWD> Under the mid point of crossmember
Rear:
<FWD> Under the jack up bracket of rear floor pan
<AWD> Under the rear differential
Cautions
1. Never use a jack at the lateral rod or rear suspension
assembly. <FWD>
2. In order to prevent scarring the centermember <MID>
I <FWD> Rear <AWD> I
or crossmember <AWD>, place a piece of cloth on the
jack’s contact surface (to prevent corrosion caused by
damage to the coating).
3. A floor jack must never be used on any part of the
underbody.
4. Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
INTRODUCTION AND MASTER TROUBLESHOOTING - Towing and Hoisting 2”1
LIFTING, JACKING SUPPORT LOCATION
-4WD>
lOA
<AWD>
--
OOAOO2 1
Floor jack locations Approximate center of gravity

*
@ Frame contact hoist, twin post hoist or scissors jack (emergency) locations
EMERGENCY JACKING
Jack receptacles are located at the body sills to accept the
scissors jack supplied with the vehicle for emergency road
service. Always block opposite wheels and jack on level
surface.
22 INTRODUCTION AND MASTER TROUBLESHOOTING - %%c%:k! ‘nstructions
SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS NWUAAB
TOWING
Towing methods Remarks
If a tow truck is used l For AWD models, the basic principle is that
Lifting method for 4 wheels-Good all four wheels are to be raised before
towing.
l The shift lever should be set to 1 st gear and
thhrting brake should be applied.
l The selector lever should be set to “P”
position and the parking brake should be
applied. <AA>
OOAO032
Front wheels lifted-No good l The vehicle must not be towed by placing
only its front wheels or only the rear wheels
on a rolling dolly, because to do so will
result in deterioration of the viscous
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.
OOA0034
Front wheels IifteddNo good l If only the front wheels or only the rear
wheels are lifted for towing, the bumper
will be damaged.
In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
llA0060
Rear wheels lifted-No good
OOA0033
Special Handling lnstruction~
INTRODUCTION AND MASTER TROUBLESHOOTING - for AWD Models 2 3
SPEEDOMETER TEST
IF A FREE ROLLER IS USED
1. Set the free roller on the floor (at the rear wheels) so that it
is aligned with the vehicle’s wheelbase and the rear tread.
7T
T Free roller
2. Carefully move the vehicle onto the tester and free roller.
3. Set the speedometer tester in place.
4. Perform the speedometer test.
For information concerning the measurement of speed and
the allowable error, refer to GROUP 8-Meters and
00P0030
Gauges.
Caution
Do not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
IF THE REAR WHEELS ARE JACKED UP
1. Move the vehicle onto the speedometer tester.
T&a
2. Jack up the rear wheels, and place axle stands at the
T Axle stand
OOPOO37
designated part of the side sill.
3. Perform the speedometer test.
For information concerning the measurement of speed and
the allowable error, refer to GROUP 8-Meters and
Gauges.
Caution
Do not operate the clutch suddenly, or increase or
Front tie-down bracket
Front wheel side slip
To prevent the front wheels from moving from side to side,
attach tension bars to the front tie-down brackets, and secure
both ends at anchor plates.
Accident prevention procedures
(1) Attach a chain or wire to the rear tie-down hole. (Refer to
GROUP 8-Meters and Gauges.) Make sure the end of the
16PO209 wire or chain is secured firmly.
(2) Take all other necessary precautions.
BRAKE TEST
In order to stabilize the viscous coupling’s dragging force, the
brake test should always be conducted after the speedometer
test.
FRONT WHEEL MEASUREMENTS
1. Place the front wheels on the brake tester.
2. Perform the brake test.
Caution
The rear wheels should remain on the ground.
14A0198
3. If the brake dragging force exceeds the specified value,
jack up the vehicle and manually rotate each wheel to
check the rotation condition of each wheel.
NOTE
If the brake dragging force exceeds the specified value, the
cause may be the effect of the viscous coupling’s dragging
force, so jack up the front wheels and check the rotation
condition of the wheels in this state for no effect by the
viscous coupling’s dragging force.
OOPO036
24 INTRODUCTION AND MASTER TROUBLESHOOTING - fSo%k%:~~it’ndrU~ions
REAR WHEEL MEASUREMENTS
After placing the rear wheels on the brake tester, follow the ~.
same procedures as for the front wheel measurements. ,’
Braking force of AWD models with VCU
Braking force
Left/right At 90kg ( 1 9 8 60% or more of
sum Ibs.) pedal de- front axle weight
pression force
Each Rear wheels: 330
wheel kg (727 Ibs.) or more
Left/right 8% or less of axle weight

difference
Total At 90kg ( 1 9 8 830 kg (1,829 Ibs.)

Ibs.) pedal de- or more*
pression force
* About 20 kg (44 Ibs.) of force by viscosity torque has been

added.
or...
I Braking-stop distance At primary velocity of 50 km/h

(31 mph): Within 16.0m (52.5 ft.)
WHEEL BALANCE .r=l

FRONT WHEEL MEASUREMENTS
1. Jack up the rear wheels, and place an axle stand at the
2. Jack up the front wheels and set a pick-up stand and
balancing machine in place.
Caution
1. Set so that the front and rear of the vehicle are at
the same height.
2. Release the parking brake.
3. Rotate each wheel manually and check to be sure
that there is no dragging.
3. Use the engine to drive the tires, and then make the
measurement.
Caution
1. If an error is indicated in the state of engine drive,
motor drive can be used concurrently.
Balancing 2. Do not operate the clutch suddenly, or increase or
machine
REAR WHEEL MEASUREMENTS
1. Jack up the front wheels, and place an axle stand at the
2. Jack up the rear wheels, and then, after setting a pick-up
stand and balancing machine in place, follow the same
procedure as for front wheel measurements. .&,
Pick-up stand
WA0024
INTRODUCTION AND MASTER TROUBLESHOOTING - :;k%ii::& and 25
GENERAL DATA AND SPECIFICATIONS NOOHA-
OOAOl59
GENERAL SPECIFICATIONS
<PLYMOUTH>
l .8L Engine 1.8L Engine 2.0L DOHC 2.0L DOHC

Items
“Medium” “High”
~%n?urbo) :Tz%$
Vehicle dimensions mm(in.)
Overall length 1 4,330 (170.5) 4,330 (170.5) 4,330 (I 70.5) 4,330 (170.5)
Overall width 2 1,690 (66.5) 1,690 (66.5) 1,690 (66.5) 1,690 (66.5)
Overall height 3 1,306 (51.4) 1,306 (51.4) 1,306 (51.4) 1,306 (51.4)
Wheel base 4 2,470 (97.2) 2,470 (97.2) 2,470 (97.2) 2,470 (97.2)
Tread Front 5 1,465 (57.7) 1,465 (57.7) 1,465 (57.7) 1,465 (57.7)
Rear 6 1,450 (57.1) 1,450 (57.1) 1,450 (57.1) 1,450 (57:l i
Overhang Front 7 950 (37.4) 950 (37.4) 950 (37.4) 950 (37.4)
z-
Rear 8 910 (35.8) 910 (35.8) 910 (35.8) 910 (35.8)
Minimum running ground 9 160 (6.3) 160 (6.3) 160 (6.3) 160 (6.3)
clearance mm (in.)
Angle of approach
degrees 10 1 5 . 3 ” 15.3” 15.3” 15.3”
Angle of departure
degrees 11 18.1” 18.1” ’ 18.1“ 18.1”
Vehicle weight kg (Ibs.)
Curb weights
M/T 1,145 (2,524) 1,165 (2,568) 1,215 (2,679) 1,245 (2,745)
AIT 1 ,I 70 (2,579) 1,190 (2,623) 1,240 (2,734) 1,280 (2,822)
Gross vehicle weight rating 1,585 (3,494) 1,585 (3,494) 1,630 (3,594) ‘I ,670 (3,682)
Gross axle weight rating
Front 900 (1,984) 900 (1,984) 930 (2,050) 965 (2,127)
Rear 685 (1,510) 685 (1,510) 700 (1,543) 705 ‘(1,554)
Seating capacity 4 4 4 4
Engine
Model No. 4G37 4637 4G63 4G63
Transaxle
Model No.
A-
Manual transaxle F5M22 F5M22 F5M22 F5M33
Automatic transaxle F4A22 F4A22 F4A22 F4A33
Clutch
Type Dry-single disc Dry-single disc Dry-single disc Dry-single disc
& diaphragm & diaphragm & diaphragm & diaphragm
spring spring spring spring
26 INTRODUCTION AND MASTER TROUBLESHOOTING - :;:%:a=and
2.0L DOHC 2.0L DOHC

Items 1.8L Engine 1.8L Engine
“Medium” “Medium” #b”;
Kr%n?u rbo)
Chassis
Tire Pl85/70R14 PI 85/70Rl4 P205/55Rl6 89H P205/55Rl6 89
or
;;5/55R16 89V 205155R16 88V
%55R16 88V
Front suspension
Type Independent Independent Independent Independent
strut strut strut strut
Rear suspension
We 3l\Fk Torsion &k-k Torsion zx;;k Torsion 3Lnk Torsion
Brake
Type Front Disc Disc Disc Disc
Rear Disc Disc Disc Disc
Steering
Gear type Rack and Rack and Rack and Rack and
pinion pinion pinion pinion
Gear ratio 03 cn co co
Fuel tank
Capacity liters (gals.) 60 (16) 60 (16) 60 (16) 60 (16)
<EAGLE>
2.0L DOHC Engine 2.0L DOHC Engine 2.0L DOHC Engine
Items
(Non-Turbo) (FWD-Turbo) (AWD-Turbo)
Vehicle dimensions mm(in.)

Overall length 1 4,330 (I 70.5) 4,350 (171.3) 4,380 (I 72.4)
Overall width 2 1,690 (66.5) 1,700 (66.9) 1,700 (66.9)
Overall height 3 1,306 (51.4) 1,306 (51.4) 1,321 (52.0)
Wheel base 4 2,470 (97.2) 2,470 (97.2) 2,470 (97.2)
Tread Front 5 1,465 (57.7) 1,465 (57.7) 1,465 (57.7)
Rear 6 1,450 (57.1) 1,450 (57.1) 1,455 (57.3)
Overhang Front 7 950 (37.4) 960 (37.8) 960 (37.8)
Rear 8 910 (35.8) 920 (36.2) 950 (37.4)
Minimum running ground 9 160 (6.3) 160 (6.3) 158 (6.2)
clearance mm (in.)
Angle of approach d e g r e e s 10 15.3 13.2” 14.0”
Angle of departure degrees 11 18.1” 18.1” 17.6”
Vehicle weight kg (Ibs.)
Curb weights
MiT 1,230 (2,712) 1,260 (2,778) 1,405 (3,097)
Al-r 1,255 (2,767) 1,295 (2,855) 1,440 (3,175)
Gross vehicle weight rating 1,630 (3,594) 1,670 (3,682) I,81 0 (3,990)
Gross axle weight rating
Front 930 (2,050) 965 (2,127) 1,005 (2,216)
Rear 700 (1,543) 705 (1,554) 805 (1,775)
Seating capacity 4 1 4
Engine
Model No. 4G63 4G63 4G63
INTRODUCTION AND MASTER TROUBLESHOOTING - f~EEaZ% acld 27
Items 2.0L DOHC Engine 2.0L DOHC Engine 2.0L DOHC Engine
(Non-Turbo) (FWD-Turbo) (AWD-Turbo)
Transaxle
Model No.
Manual transaxle F5M22 F5M33 W5M33
Automatic transaxle F4A22 F4A33 W4A33
Clutch
Type Dry-single disc Dry-single disc Dry-single disc
& diaphragm spring & diaphragm spring & diaphragm spring
Chassis
Tire P205/55R16 89H P205155R16 89V P205/55R16 89V
o r 205/55R16 89V o r 205/55R16 88V o r 205/55R16 88V
o r 205/55R16 88V
Front suspension
Type Independent strut Independent strut Independent strut
Rear suspension
Type 3-Link Torsion axle 3-Link Torsion axle Double wishbone
Brake
Type Front Disc Disc Disc
Rear Disc Disc Disc
Steering
Gear type Rack and pinion Rack and pinion Rack ,and pinion
Gear ratio 03 co cc
=r Fuel tank
Capacity liters (gals.) 60 (16) 60 (16) 60 (16) )
ENGINE SPECIFICATIONS
Items 4G37 4G63 Non-Turbo 4G63 Turbo
Type In-line SOHC In-line DOHC In-line DOHC

Number of cylinders 4 4 4
Bore mm (in.) 80.6 (3.17) 85.0 (3.35) 85.0 (3.35)
Stroke mm (in.) 86.0 (3.39) 88.0 (3.46) 88.0 (3.46)
Piston displacement cm3 (cu.in.) 1,755 (107) 1,997 (122) 1,997 (122)
Compression ratio 9.0 9.0 7.8
Firina order 1-3-4-2 1-3-4-2 1-3-4-2
TRANSAXLE SPECIFICATIONS
Items F5M22 F5M33 W5M33 F4A22 F4A33 W4A33
Type 5-speed M/T 5-speed M/T 5speed M/T 4-speed A/T 4-speed AIT Qspeed AIT
Gear ratio 1 st 3.363 3.090 3.083 2.846 2.551 2.551
2nd 1.947 1.833 1.684 1.581 1.488 1.488
3rd 1.285 1.217 1.115 1.000 1 .ooo 1 .ooo
4th 0.939 0.888 0.833 0.685 0.685 0.685
5th 0.756 0.741 0.666 - - -
9..
Reverse 3.083 3.166 3.166 2.176 2.176 2.176

Transaxle
Primary reduction ratio 1.096 1.208 1.275 1.125 1.228 1.228
Secondary reduction ratio 3.941 3.437 3.866 3.562 3.222 3.600
Transfer - 1.090 - - 1.090
28 INTRODUCTION AND MASTER TROUBLESHOOTING - Tightening Torque
TIGHTENING TORQUE NOOJA-
Each torque value in the table is a standard value for tightening under the following conditions.
(1) Bolts, nuts and washers are all mode of steel and plated with zinc.
(2) The threads and bearing surface of bolts and nuts are all in dry condition.
The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast inserted nuts.
(4) If self-tapping screws or self-locking nuts are used.
Standard bolt and nut tightening torque
I
L
Flange bolt and nut tightening torque
Bolt nominal Pitch Torque Nm (ftlbs.)

(mm)
KTter Head mark 04 Head mark 07 Head mark 08
M6 1 .o 4 - 6 (2.9-4.3) 8-l 2 (5.8-8.7) 9 - 1 4 (6.5-10)
M8 1.25 IO-15 (7.2-11) 19-28 (14-20) 22-33 (16-24)
Ml0 1.25 21-31 (15-22) 39-60 (28-43) 50-65 (36-47)
Ml0 1.5 19-29 (14-21) 3 6 - 5 4 (26-39) 45-65 (33-47)
Ml2 1.25 38-55 (27-40) 80- 110 (58-80) 90- 120 (65-87)
Ml2 1.75 34-52 (25-38) 70-95 (51-69) 85-l 10 (61-80)
Taper thread tightening torque
Torque Nm (ftlbs.)
Thread size
Female thread material: Light alloy Female thread material: Steel
NPTF l/6 5-8 (3.6-5.8) 8-12 (5.8-8.7)
PT l/8 8- 12 (5.8-8.7) 16’-20 (12-14)
PT l/4, NPTF I/4 20-30 (14-22) 35-45 (25-33)
PT 318 40-55 (29-40) 60-75 (43-54)
NOTE: NPTF is dry seat pipe thread, while PT is pipe thread.
INTRODUCTION AND MASTER TROUBLESHOOTING - Mast& Tro6blerhootbia
MASTER TROUBLESHOOTING 7*
I, ._ ,...
r. ENGINE OVERHEATS i”
Symptom Probable cause Reference page : I
._),
Engine overheats Cooling system faulty 7-5
Incorrect ignition timing 8-169
ENGINE WILL NOT CRANK OR CRANKS SLOWLY

Symptom Probable cause Reference page
Engine will not crank Starting system faulty ,’ 8-153

or cranks slowly
ENGINE WILL NOT START OR HbRD TO START (CRANKS OK)

Engine will not start or hard to No fuel supply to injector -

start (Cranks OK)
Injection system problems -
Ignition system problems 8-16!$ / ;”

..“,
Vacuum leaks 11-5 :’
l Purge control valve hose 25-4
l Vacuum hoses
l Intake manifold
l Air intake plenum
l Throttle body
l EGR valve
Compression too low g-23, ‘, :. ” ‘,;A;
ROUGH IDLE OR ENGINE STALL

“. ._
Symptom Probable cause Reference page or remedy
Rough idle or engine stalls Vacuum leaks 11-5

l Vacuum hoses
l Intake manifold
l Air intake plenum
l Throttle body
l EGR valve
Ignition system problems 8-169
Idle speed set too low Check idle speed control sys-
tem
Idle mixture too lean or too rich -
Fuel injection system problems -
Exhaust gas recirculation (EGR) system 25-l 5

problems
Engine overheats 7-5
Compression too low 9-23

30 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
ENGINE HESITATES OR POOR ACCELERATION

Engine hesitates or poor Ignition system problem 8-169

acceleration
Vacuum leaks 11-5
l Vacuum hoses
l Intake manifold
l Air intake plenum
l Throttle body
l EGR valve
Air cleaner clogged -
Fuel line clogged -
Fuel injection system problem -
Emission control system problem 25-15

l EGR system always on
Engine overheats 7-5
Compression too low 9-23
ENGINE DIESELING
Engine dieseling (runs after Incorrect ignition timing 8-169

ignition switch is turned off)
EXCESSIVE OIL CONSUMPTION
Excessive oil consumption Oil leak Repair as necessary.
Positive crankcase ventilation line clogged. 25-7

Valve stem seal worn or damaged. g-55.114
Valve stem worn. g-55.114
Piston ring worn or damaged. g-66,128
INTRODUCTION AND MASTER TROUBLESH’OOTING .- Master ~pAi&oOti~ 31
POOR FUEL MILEAGE ‘, ../,_I, *,, #_ /S./..

.a,‘. r ?
Symptom Probable cause Reference page or remedy”
Poor fuel mileage Fuel leak Repair as necessary.
Air cleaner clogged. -
Ignition system problems 8-169
I Fuel injection system problems. I

-
I
Compression too low. 9-23
Tires improperly inflated. 22-3
Clutch slips. 6-4
Brakes drag. 5-7

I
NOISE
Noise Loose bolts and nuts. Retighten as necessary
Engine noise 9-23 ’
HARD STEERING
Hard steering Loose power steering oil pump belt 19-12
Low fluid level Replenish
Air in power steering system 19-13
Low tire pressure 22-3
Excessive turning resistance of lower arm ball 2-35
Excessively tightened of steering gear box 1 i-23.30
I Improper front wheel alignment 2-8
Excessive turning resistance of tie-rod ball 19-8.10

ioint
Sticky flow control valve 19-41
Bent rack in steering gear box ‘. 19-23.30
POOR RETURN OF STEERING WHEEL TO CENTER

Symptom 1 Probable cause I Reference page I
Poor return of steering wheel to Improper front wheel alignment 2-8
center
Improper tire pressure 22-3
Excessive tightened rack support cover 19-23.30
I-- ~~~
Damaged front wheel bearing I 2-12 I
POOR RIDING
/-=..
Symptom Probable cause Reference page or remedy \
Poor riding Improper tire pressure 22-3
lmbalanced wheels Repair
Improper front or rear wheel alignment 2-8,29

17-3.20
Malfunctioning shock absorber
Broken or worn stabilizer 2-29,37,42

_ 17-8,32,35
Broken or worn coil spring
Loose suspension securing bolt(s) Retighten
Worn lower arm bushing 2-33
Worn suspension arm bushing 2-33 Y,’ ,>’
ABNORMAL TIRE WEAR

Abnormal tire wear Improper front or rear wheel alignment 2-8

1 17-3.20 I
I
lmbalanced wheels
I I
Loose wheel bearings 17-3
Malfunctioning shock absorber 2-29
17-8,32
ROAD WANDER
Road wander Improper front or rear wheel alignment 2-8

17-3.20
Excessive play of steering wheel 19-7.10
Poor turning resistance of lower arm ball joint 1 2-35 I
Loose or worn lower arm bushing 2-33
Loose or worn wheel bearings

Loose rack support cover in steering gear box 19-23,30
INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
VEHICLE PULLS TO ONE SIDE

Symptom Probable cause Reference page I
Vehicle pulls to one side Improper front or rear wheel alignment 2-8
17-3,20
lmbalanced or worn tires 22-3
Uneven tire pressure
Excessive turning resistance of lower arm ball 2-35

joint
Wheel bearing seizure Replace
Broken or weak coil spring 2-29
Bent front axle drive shaft 2-15,3-13
Deformed lower arm 2-35
STEERING WHEEL SHIMMY

Steering wheel shimmy Improper front or rear wheel alignment 2-8

17-3,20
lmbalanced wheels Replace
Poor turning resistance of lower arm ball joint 2-35
Excessive play of steering wheel 19-7,lO
Broken or weak front stabilizer 2-33
Worn lower arm bushing 2-33
Malfunctioning shock absorber 2-29

17-8,32
Broken or weak coil spring
Wear, play, or seizure of wheel bearing Replace
Wear, play, or seizure of drive shaft ball joint 2-15.3-13

L
BOTTOMING
I-Svmotom Probable cause 1 Reference page or remedy [
Bottoming Overloaded vehicle Correct
Broken or weak coil spring 2-29

l7-8,32
Malfunctioning shock absorber
WHEEL BEARING TROUBLESHOOTING

Trouble Sympton Probable cause
Pitting Pitting occurs because of uneven rotation of race Excessive bearing preload
and bearing surfaces Excessive load’
Flakrng The surface peels because of uneven rotation of End of bearing life
the race and bearing surfaces Improper bearing assembly
Crackrng Chipping or cracking of cage or roller edges Impact when bearing was installed
(such as being hit with a hammer)
Flat spotting When large load is applied, race and roller Excessive bearing preload
contact surfaces compress, forming Excessive load
indentations Vibration when bearings are not
used, such as during shipment on
freight cars, transport trucks, etc.
Nicks Instead of rolling along race surface, rollers slide, Insufficient grease
thus damaging surface Excessive bearing preload
Excessive load
Faulty oil seal
Smearing Damage or wear caused by minute particles Excessive variation of loads on ” .j’
adhering to surfaces results in rough movement bearings
and such high temperatures that parts of surface Use of grease other than that
melt specified
Insufficient grease
Rust, corrosion Appears on various areas of the bearing Use of grease other than that
specrfied
Faulty oil seal
Presence of water or moisture
wear Wear of surface areas caused by friction Insufficient grease

Foreign matter
Rust or corrosion due to moisture
Use of grease other than that
specified
Faulty oil seal
3rscoloration Grease discoloration results from grease Jse of grease other than that
deterioration which causes particles of specified
pigment contained in grease to adhere -aulty oil seal
to surfaces lxcessive bearing preload
Heat discoloration will appear Excessive load
as a deep brown on purple
LUBRICATION AND’ I
MAINTENANCE
CONTENTS
GENERAL INFORMATION .............................. 2 Engine Oil Filter ........................................... 9

Exhaust System ............................................ 13
MAINTENANCE SERVICE ............................... 7
Fuel Hose ..................................................... 7
Air Cleaner Element ..................................... 7
Fuel System ................................................. 7
Automatic Transaxle.................................... 11
Manual Transaxle .......................................... 10
Ball Joint and Steering Linkage Seals ........ 13 13
Rear Axle ......................................................
Brake Hoses ................................................. 12
Spark Plugs ................................................... 8
-lb Disc Brake Pads ........................................... 12
Timing Belt ...................................................... 8
Drive Belt (For Water Pump and
Alternator) ..................................................... 8 RECOMMENDED LUBRICANTS AND
Drive Shaft Boots ......................................... 13 LUBRICANT CAPACITIES TABLE .................. 4
Engine Coolant ............................................. 12
SCHEDULED MAINTENANCE TABLE ............ 3
Engine Oil ..................................................... 9
o-2 LUBRICATION AND MAINTENANCE - General Information
Caution
GENERAL INFORMATION NGQPA--
Test results submitted to EPA have shown that
Maintenance and lubrication service recommenda- laboratory animals develop skin cancer after
tions have been compiled to provide maximum prolonged contact with used engine oil. Accor-
protection for the vehicle owner’s investment dingly, the potential exists for humans to de-
against all reasonable types of driving conditions. velop a number of skin disorders, including
Since these conditions vary with the individual cancer, from such exposure to used engine oil.
vehicle owner’s driving habits, the area in which the Care should be’ taken, therefore, when changing
vehicle is operated and the type of driving to which engine oil, to minimize the amount and length of
the vehicle is subjected, it is necessary to prescribe exposure time to used engine pi! on your skin.
lubrication and maintenance service on a time Protective clothing and gloves, that cannot be
frequency as well as mileage interval basis. penetrated by oil, should be worn. The skin
Oils, lubricants and greases are classified and should be thoroughly washed with soap and
graded according to standards recommended by the water, or use waterless hand cleaner, to remove
Society of Automotive Engineers (SAE), the Amer- any used engine oil. Do not use gasoline,
ican Petroleum Institute (API) and the National thinners, or solvents.
Lubricating Grease Institute (NLGI).
GEAR LUBRICANTS
MAINTENANCE SCHEDULES The SAE grade number also indicates the viscosity
Information for service maintenance is provided of Multi-Purpose Gear Lubricants.
under “SCHEDULED MAINTENANCE TABLE”. The API classfication system defines gear lubricants
Three schedules are provided; one for “Required in terms of usage. Typically gear lubricants conform-
Maintenance”, one for “General Maintenance” and ing to API GL-4 or GL-5 with a viscosity of SAE
one for “Severe Usage Service”. 75W-85W are recommended for manual transaxle.
Item numbers in the “SCHEDULED MAINTE-
NANCE TABLE” correspond to the item numbers in LUBRICANTS - GREASES
the “MAINTENANCE SERVICE” section.
Semi-solid lubricants, bear the NLGI designation and
SEVERE SERVICE are further classified as grades 0, 1, 2, 3 etc.
Vehicles operating under severe service conditions Whenever “Chassis Lubricant” is specified, Multi-
will require more frequent service. Purpose Grease, NLGI grade 2 should be used.
Component service information is included in MOPAR Multi-Mileage Lubricant, P&t Number
appropriate units for vehicles operating under one or 2525035 or equivalent, meets these requirement
more of the following conditions: and is recommended.
1. Trailer towing or police, taxi, or commercial type
operation FUEL USAGE STATEMENT
2. Operation of Vehicle Use gasolines having a minimum anti-knock index
(1) Short-trip operation at freezing temperature (Octane Value) of 87, (R + M)/2. This designation is
(engine not thoroughly warmed up) comparable to a Research Octane Number of 91.
(2) More than 50% operation in heavy city Unleaded gasolines only must be used in vehicles
traffic during hot weather above 32°C (90°F) equipped with catalyst emission control systems.
(3) Extensive idling All vehicles, so equipped, have labels located on the
(4) Driving in sandy areas instrument panel and on the back of fuel filler lid that
(5) Driving in salty areas state, “UNLEADED GASOLINE ONLY”. These vehi-
(6) Driving in dusty conditions cles also have fuel filler tubes especially designed to
accept the smaller diameter unleaded gasoline
ENGINE OIL dispensing nozzles only.
The SAE grade number indicates the viscosity of
engine oils, for example, SAE 30, which is a single MATERIALS ADDED TO FUEL
grade oil. Engine oils are also identified by a dual Indiscriminate use of fuel system cleanng agents
number, for example, SAE lOW-30, which indicates should be avoided. Many of these materials in-
a multigrade oil. tended for gum and varnish removal may contain
The API classification system defines oil perform- highly active solvents or similar ingredients that can
ance in terms of engine usage. Only engine oil be harmful to gasket and diaphragm materials used
designed “For Service SG” or “For Service SGKD”, in fuel system component parts.
when available, should be used. These oils contain
sufficient chemical additives to provide maximum
engine protection. Both the SAE grade and the API
designation can be found on the container.
. &3
LUBRICATION AND MAINTENANCE - Scheduled MaintenanCe Table
1
SCHEDULED MAINTENANCE TABLE
- SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PRO;;
VEHICLE PERFORMANCE
Inspection and Services should be performed any time a malfunction is observed or suspected. Retain
receipts for all vehicle emission services to protect your emission warranty.
Kilometers in Thousands 24 48 72 80 96
No. Emission Control System Maintenance Service Intervals
Mileage in Thousands 15 30 45 50 60
1 Check Fuel System (Tank, Line and Connections and Fuel Filler Cap) for Leaks
Every 5 Years or X
2 Check Fuel Every 2 Years for Leaks or Damage or X X

3 Replace Air Cleaner Element at X X
4 Replace Spark Plugs at X X
GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

Kilometers in Thousands 24 48 72 80 9c
Yo. General Maintenance Service Intervals
Mileage in Thousands 15 30 45 50 6C
5 Timing Belt (Including the

Balancer Belt) Replace at X
Drive Belt (for Water Pump

6 Inspect for tension at X X
and Alternator) .’
Every 12 000 km
Non-Turbo Change Every Year Or ( 7 , 5 0 0 miles).
7 Engine Oil
Every 8,000 km
Turbo Change Every 6 Months
(5,000 miles)
Non-Turbo Change Every Year or X X X X

8 Engine Oil
Filter Every 16,000 km
Turbo Change Every Year (10,000 miles)
9 Manual Transaxle Oil Inspect Oil Level at X .X
Inspect Fluid Level Every Year or X X X X

10 Automatic Transaxle Fluid
Change Fluid at X X
11 Engine Coolant Replace Every 2 Years or X X

12 Disc Brake Pads Inspect for Wear Every Year or X X X X
13 Brake Hoses Check for Deterioration or Leaks Every Year X X X X
l4 Beiloint and Steering Linkage inspect for Grease Leaks and Damage Every or X
2 Years X
15 Drive Shaft Boots Inspect for Grease Leaks and Damage Every Year or X X X X
With LSD Change Oil X X

16 Rear Axle
<AWD> Inspect Oil Level X X
Exhaust System (Connection
17 Portion of Muffler, Pipings and Check and Service as Required Every 2 Years or x - x
Converter Heat Shields)
NOTE
LSD: Limited-slip differential
Scheduled Maintenance Table/Recommended Lubricants
0-4 LUBRICATION AND MAINTENANCE - and Lubricant Capacities Table
SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

The maintenance items should be performed according to the following table: F.
Mileage Intervals Kilometers in Thousands Severe Usage
(Miles in Thousands) Conditions
Service to be
Maintenance Item
Performed
24 36 48 60 72 80 84 96
(:,:) (15) (22.5) (30) (37.5) (45) (50) (52.5) (60) * B ’ D E F G
Air Cleaner Replace More Frequently X X

Element
Spark Plugs Replace X X X x xx
Engine Oil $$~~~h~vev o r Every 4,800 km (3,000 miles) xxxx x
Engine Oil Filter Replace Every or xxxx x

Every 9,600 km (6,000 miles)
6 Months
Disc Brake Pads Inspect for Wear More Frequently X X

Severe usage conditions
A-Driving in dusty conditions E-Driving in sandy areas
B-Trailer towing or police, taxi, or commercial type F-Driving in salty areas
operation G-More than 50% operation in heavy city trafic during
C-Extensive idling hot weather above 32°C (90°F)
D-Short trip operation at freezing temperatures
(engine not thoroughly warmed up)
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE

NOONA- --z.
/
RECOMMENDED LUBRICANTS
Items Recommended lubricants
Engine Oil kF&cesisification SG or SG/CD (For further details, refer to SAE viscosity
Manual Transaxle MOPAR Hypoid Gear Oil/API classification GL4 or higher, SAE 75W-
85W
Transfer
Automatic Transaxle MOPAR ATF PLUS (Automatic Transmission Fluid Type 7176) or Dia
ATF SP or Equivalent
Power Steering MOPAR ATF PLUS (Automatic Transmission Fluid Type 7176VAutomatic
transmission fluid or “DEXRON” or “DEXRON II”
Rear Axle <AWD> Refer to P.O-6.
Brake and Clutch MOPAR Brake Fluid/Conforming to DOT 3
Rear Wheel Bearings MOPAR Front Wheel Bearing Grease, or MOPAR Multi-Mileage
Lubricant/Multipurpose grease NLGI Grade 2EP
Hood Lock Latch,, Door Lock Strikers, MOPAR Lubriplate/Multipurpose grease NLGI Grade 2
Seat Adjusters, Lrftgate Lock, Parking
Brake Cable Mechanism
Engine Coolant MOPAR Antifreeze Permanent-Type Coolant/High quality ethylene-glycol N

antifreeze coolant
Door Hinges, Liftgate Hinges Engine oil
LUBRICATION AND MAINTENANCE - and
Recommended Lubrie’nts Table
Lubrtcant Capacttles
LUBRICANT CAPACITIES TABLE

Description Metric measure U.S. measure
Engine Oil
Crankcase (including oil filter)
<1.8L Engine> 3.9 liters’. 4.‘1 qts.
<2.0L DOHC Enaine>
Engine> 4.4 liters 4.6 qts.
Oil filter 0.4 liter ‘h q t .
Oil cooler (Turbo) 0.3 liter Y2 q t .
Cooling System (including heater and coolant reserve system)

 6.2 liters 6.6 qts.
<2.0L DOHC Engine> 7.2 liters 7.6 qts.
Manual Transaxle
<Non-Turbo> 1.8 liters 1.9 qts.
<FWD-Turbo> 2.2 liters 2.3 qts.
<AWD-Turbo> 2.3 liters 2.4 qts.
Transfer I 0.6 liter I .63 qt.
Au:oFmqaAtF2pnsaxle
6.1 liters 6.4 qts.
<F4A33. W4A33> 7.0 liters 7.4 qts.
Rear Axle <AWD> 0.7 liter .74 qt.
Power Steering 0.9 liter .95 sf.
Fuel Tank 60 liters 15.9 gal?.
SELECTION OF LUBRICANTS ’ ~ “.
ENGINE OIL
Engine oil should be used which conform to the requirements
"C “F of the API classification “For Service SG” or “For Service
49 120 SGKD”, and have the proper SAE grade number for the
expected temperature range.
40 104
Caution
Nondetergent or straight mineral oil must never be used.
27 80 Energy Conserving Oil
In order to improve fuel economy and conserve energy new,
16 60 lower friction engine oils have been developed. These oils are
10 50 readily available and can be identified by such labels as “Energy
Conserving”, “Energy Saving”, “Improved Fuel Economy”,
0 32 etc.
-10 14
-15 5
-20 -4
-23 -10
-29 -20
/”
SAE 5W-20 Not recommended for sustained
high speed vehicle operation.
**SAE 5W-30 may be used for operation in very
cold weather areas where the lowest atmos-
pheric temperature is below -23°C (-10°F).
Recommended Lubricants and Lubricant
O-6 LUBRICATION AND MAINTENANCE - Capacities Table
Oil Identification Symbol

A standard symbol appears on the top of oil containers and has
three district areas for identifying various aspects of the oil.
The top portion will indicate the quality of the oil. The center
portion will show the SAE viscosity grade, such as SAE
IOW-30. “Energy Conserving” shown in the lower portion,
indicates that the oil has fuel-saving capabilities.
72A0044
REAR AXLE
Lubricant API classification

GL-5 or higher
Anticipated temperature range Viscosity range
Above -23°C (-10°F) SAE 90
SAE 85W-90
SAE 8OW-90
-23°C to -34°C (-10°F to -30°F) SAE 8OW, SAE 8OW-90
Below -34°C (-30°F) SAE 75W
SELECTION OF COOLANT
COOLANT
Relation between Antifreeze Concentration and Specific Gravity
concentration
Example
The safe operating temperature is - 15°C (5°F) when the measured specific gravity is 1.058 at the coolant
temperature of 20°C (68°F).
Cautions
1. If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling
properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the
concentration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
LUBRICATION AND MAINTENANCE - Maintenance Service
MAINTENANCE SERVICE
1. FUEL SYSTEM (Tank, Lines, Connect%ms and
Fuel Filler Cap) (Check for leaks)/2. FUEL
HOSE (Check for leaks or damage) 1 NSOSAGtib
1. Check for damage or leakage in the fuet lines and

connections and looseness of the fuel fi!:ler cap.
2. Inspect the surface of fuel hoses for heat and mecha-
nical damage. Hard and brittle rubber, cracking, check-
ing, tears, cuts, abrasions and excessive swelling
indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by
cracks and abrasions in the fuel system, the hoses
should be changed.
3. AIR CLEANER ELEMENT (Replace) NOOSAKBb
The air cleaner element will become dirty and loaded with
dust during use, and the filtering effect will be substantially
reduced. Replace it with a new one.
<1.8L Engine, 2.0L DOHC Engine (Non-Turbo)>
(1) Disconnect the air-flow sensor connector.
(2) Remove the air intake hose.
(3) Unclamp the air cleaner cover.
(4) Push the air intake hose backward, and remove the air
cleaner cover.
Caution
Care must be taken when removing the air cleaner
cover, because the air-flow sensor is ‘attached.
(5) Take out the air cleaner element.
<2.0L D O H C E n g i n e ( T u r b o ) >
(2) Disconnect the boost hose.
(3) Disconnect the solenoid valve with hoses.
(4) Disconnect the air intake hose.
(5) Remove the air cleaner retaining bolts.
(6) Remove the air cleaner assembly.
Caution
cover, because the air-flow sensor is attached.
O-8 LUBRICATION AND MAINTENANCE - Maintenance Service
4. SPARK PLUGS (Replace) NOOSAOFa
1. Spark plugs must spark properly to assure proper ~

engine performance and reduce exhaust emission
0-L level.
Therefore, they should be replaced periodically with
I-T new ones.
2. The new plugs should be checked for the proper gap.
Spark plug gap
<Non-Turbo> 1.0-1.1 mm (.039-.043 in.)
<Turbo> 0.7-0.8 mm (.028-.031 in.)
OlLO182
-
3. Install the spark plug and tighten to 20-30 Nm (15-21
ft.lbs.).
5. TIMING BELT (Replace) NOOSBACa
Replace the belt with a new one periodically to assure

proper engine performance.
For removal and installation procedures, refer to GROUP
g-Timing Belt.
6. DRIVE BELT (For Water Pump and Alternator)

(Inspect for tension) NOOSSBN
(1) Place straight edge as shown in the illustration.

(2) Measure the deflection with a force of 100 N (22 Ibs.) rz
applied to belt mid-point between water pump pulley -
and alternator pulley. If the standard value is not
obtained, make adjustment.
Standard value:
<1.8L Engine> 8.0-11.0 mm (.315-A33 in.)
, ,
6COOO9
<2.0L DOHC Engine>
9.0-11.5 mm (.354-.453 in.)
(3) Use a tension gauge to check the belt tension. If the
standard value is not obtained, make adjustment.
When tension gauge is used, the tension may be
measured between any two pulleys.
Standard value: 250-500 N (55-110 Ibs.)
u 6COO39
LUBRICATION AND MAINTENANCE - Maintenance Service O-9
7. ENGINE OIL (Change) NWSAAF
Always use lubricants which conform to the requirements

of the API classification “For Service SG” or “For Service
SGKD” .when available, and have the proper SAE grade
number for the expected temperature range.
Never use nondetergent or straight mineral oil.
(1) After warming up the engine, remove the oil filler cap.
(2) Remove the drain plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one and
tighten the drain plug.
01R0340 (4) Supply new engine oil through the oil filler.
Engine oil total capacity:
< 1.8L Engine> 3.9 liters (4.1 qts.)
<2.0L DOHC-Non-Turbo> 4.4 liters (4.8 qts.)
<2.0L DOHC-Turbo> 4.7 liters (5.0 qts.1
[including oil filter 0.4 liter (l/2 qt.)]
(5) Start and run the engine a few minutes.
(6) Stop the engine and check the engine oil level.
8. ENGINE OIL FILTER (Change) NOO!SABGa
The quality of replacement filters varies considerably. Only

high quality filters should be used to assure most efficient
service.
Genuine oil filters require that the filter is capable of
withstanding a pressure of 256 psi .are high quality filters
and are recommended as follows:
Oil Filter Part No.
Mitsubishi Genuine Parts: MD031805 or equivalent
NOTE
Factory installed Mitsubishi Engine Oil Filter Part
No.MD084693 or MD031805.
’
ENGINE OIL FtLTER SELECTtON
This vehicle is equipped with a full-flow, throw-away oil ,~
filter.
The same type of replacement filter is recommended as a
replacement filter for this vehicle. It is possible, particularily
in cold weather, that this vehicle may develop high oil
pressure for a short duration. You should be sure that any
replacement filter used on this vehicle is a high-quality filter
and is capable of withstanding a pressure of 256 psi
(manufacturer’s specifications) to avoid filter and engine
damage. The following is a high-quality filter and is strongly
recommended for use on this vehicle : Mitsubishi Engine
Oil Filter Part No. MD031805 or MD084693. -
Any replacement oil filter should be installed in accordance
with the oil filter manufacturer’s installation instructions.
(1) Remove the engine oil filler cap.
(2) Remove the engine oil drain plug, and drain out the
engine oil.
(3) Remove the engine oil filter by using the oil filter
wrench.
(4) Clean the oil filter mounting surface of the oil filter
bracket.
(5) Coat engine oil to the O-ring of new oil filter.
(6) Turn the oil filter by hand to install to the block.
NOTE
The oil filter tightening torque is 11-13 Nm (8-10
ftlbs.).
A
(7) Supply engine oil.
(8) Start and run engine and check for engine oil leaks. .
(9) After stopping engine, check oil level and replenish as
necessary.
9. MANUAL TRANSAXLE (Inspect oil level)

NOOSBCEb
Inspect each component for evidence of leakage, and

check the oil level by remaining the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
1. With the vehicle parked at a level place, remove the
filler plug and check to be sure that the oil level is up to
the lower edge of the filler plug hole.
2. Check to be sure that the transmission oil is not
noticeably dirty, and that it has a suitable viscosity.
osFol2
LUBRICATION AND MAINTENANCE - Maintenance Service O:ll
lO.AUTOMATIC TRANSAXLE (Inspect fluid I~~+v~!
1. Drive until the fluid temperature reaches the usual
temperature [70-80°C (160- 18O”F)l.
2. Place vehicle on level floor.
3. Move selector lever sequentially to every position to fill
torque converter and hydraulic circuitwith fluid, then
place lever in “N” Neutral position. This operation is
necessary to be sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the
condition of the fluid.
The transaxle should be overhauled under the following
conditions.
l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
l If there is a noticeably great amount of metal
particles in the fluid.
5. Check to see if fluid level is in “HOT” range on dipstick.
If fluid level is low, add ATF until level reaches “HOT”
range.
Low fluid level can cause a variety of conditions
because it allows pump to take in air along with fluid. Air
trapped in hydraulic circuit forms bubbles which make
fluid spongy. Therefore, pressures will be erratic.
Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of ATF.
transmission fluid.
In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch,
and servo operation. Foaming can also result in fluid
escaping from transaxle vent where it may be mistaken
for a leak.
6. Be sure to examine fluid on dipstick closely.
lO.AUTOMATIC TRANSAXLE (Change fluid)
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new fluid after the cause of any contamina-
tion has been corrected.
(1) Remove drain plugs to let fluid drain.
(2) Remove the oil pan.
(3) Check the oil filter for clogging and damage and replace
if necessary.
(4) Clean the inside of oil pan and 5 magnets.

(5) Attach the five magnets to the concave part of the oil
(6) Elan both gasket surfaces of transaxle case and oil

pan.
(7) Install oil pan with new gasket and tighten oil pan bolts
t o IO-12 Nm (7.5-8.5 ft.lbs.1
(8) Tighten drain plug with gasket to 30-35 Nm (22-25
ftlbs.).
(9) Supply 4 liters (8.5 pints) of specified ATF into case
through dipstick hole. [Total quantity of ATF required is
6.1 liters (12.9 pints).
Actually however, approx. 4.5 liters (9.5 pints) of fluid
can be replaced because rest of fluid remains in torque
converter.]
Specified fluid: MOPAR ATF PLUS (Automatic
Transmission Fluid Type 7176) or
L-4
Good
Dia ATF SP or Equivalent
(10)Start engine and allow to idle for at least two minutes.
OOA0051 C9FW10
Then, with parking brake on, move selector lever
momentarily to each position, ending in “N” Neutral
position.
(1 l)Add sufficient ATF to bring fluid level to lower mark.
Recheck fluid level after transaxle is at normal operating
temperature.
Fluid level should be between upper and lower marks of
“HOT” range. Insert dipstick fully to prevent dirt from
entering transaxle.
11 .ENGINE COOLANT (Change) NOOSBEAc
Check the cooling system parts, such as radiator, heater,

and oil cooler hoses, thermostat and connections for
leakage and damage.
CHANGE COOLANT
1. Remove the radiator cap.
2. Loosen the drain plug to drain the coolant.
3. Drain the coolant from the reserve tank.
4. After draining the coolant, tighten the drain plug
securely.
5. Supply the coolant into the radiator until it is filled up to
its filler neck.
6. Supply the coolant into the reserve tank.
7. After warming the engine until the thermostat opens,
remove the radiator cap and check the coolant level.
8. Supply the coolant into the radiator until it is filled up to
its filler neck, and install the .radiator, cap securely.
9. Fill the reserve tank with coolant up to the “FULL” line.
12DISC BRAKE PADS (Inspect for wear) NOOSBFA~
Check for fluid contamination and wear. Replace complete

set of pads if defective.
Caution
The pads for the right and left wheels should be
replaced at the same time. Never “split” or intermix
brake pad sets.
All four pads must be replace as a complete set.
Thickness of lining (A)
14K512 Limit : 2.0 mm (.08 in.)
LUBRICATION AND MAINTENANCE - Maintenance Service o-13
13.BRAKE HOSES (Check for deteriorati.on or
leaks) NwBBnAs
Inspection of brake hoses and tubing should be included in
all brake service operations.
The hoses should be checked for:
1. Correct length, severe surface cracking, pulling, scuf-
fing or worn spots. (If the fabric casing of the hoses is
exposed by cracks of abrasion in the rubber hose cover,
the hoses should be replaced. Eventual deterioration of
hose may occur with possible bursting failure.)
2. Faulty installation, casing twisting or interference with
wheel, tire of chassis.
14.BALL JOINT AND STEERING LINKAGE SEALS
(Inspect for grease leaks and damage) NWSBJAb
1. These components, which are permanently lubricated
at the factory, do not require periodic lubrication.
Damaged seals and boots should be replaced to
prevent leakage or contamination of the grease.
2. Inspect the dust cover and boots for proper sealing,
leakage and damage. Replace them if defective.
15.DRIVE SHAFT BOOTS (Inspect for grease leaks

and damage) NWSBJAc
1. These components, which are permanently lubricated

at the factory, do not require periodic lubrication.
Damaged boots should be replaced to prevent leakage
or contamination of the grease.
2. Inspect the boots for proper sealing, leakage and
damage. Replace it if defective.
16.REAR AXLE (CONVENTIONAL DIFFERENTIAL)

(Inspect oil level)-AWD NWSBFCa
Remove the filler plug and inspect the oil level at bottom of
filler hole. If the oil level is slightly below the filler hole, it is
in satisfactory condition.
16.REAR AXLE (LIMITED-SLIP DIFFERENTIAL)

(Oil change)-AWD N66SBFCc
Before changing the rear axle oil, check to make sure that
there is no oil leakage from the rear axle housing.
Remove the drain plug and drain out of the oil.
Put the oil plug back in place, and then pour new oil in
OOAOlB6 through the filler hole.
17.EXHAUST SYSTEM (CONNECTION PORTION

OF MUFFLER, PIPING AND CONVERTER HEAT
SHIELDS) (Check and service as require$dBu.
1. Check for holes and gas leaks due to damage, corro-
sion, etc.
2. Check the joints and connections for looseness and gas
leaks.
3. Check the hanger rubber and brackets for damage.
NOTES
FRONT
SUSPENSION ’
CONTENTS NOZAA-
CENTERMEMBER AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CROSSMEMBER .............................................. 44
SPECIFICATIONS ............................................. 2
DRIVE SHAFT .................................................. 15 General Specifications .................................. 2
Lubricants ...................................................... 5
HUB AND KNUCKLE ...................................... 9
Service Specifications ................................... 4
LOWER ARM ................................................... 33 Torque Specifications ................................... 4
~ SERVICE ADJUSTMENT PROCEDURES.. ..... 8 STABILIZER BAR ............................................. 37

Front Wheel Alignment ................................ 8
STRUT ASSEMBLY ......................................... 29
Hub End Play Inspection ............................. 8
Wheel Bearing Adjustment .......................... 9
2-2 FRONT SUSPENSION - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NOZCA-
<FWD>
Items Vehicles with 1.8L Engine Vehicles with 2.0L DOHC Vehicles with 2.0L DOHC
Engine <Non-Turbo> Engine <Turbo>
MIT M M/T AIT MIT NT
Suspension system McPherson strut with’ coil spring and compression’ rod type
Coil spring
Wire dia. x0.D. x 13.4x173.4x 13.6x173.6x 13.7x173.7x 13.9x173.9x 13.9x173.9x 1 4 . 1 x174.1x
free length 326.5 (.53x 334.5 (.54x 314 (.54x 321.5 (.55x 321.5 (.55x 329 (.55x
mm (in.) 6.83x12.9) 6.83x 13.2) 6.84x 12.4) 6.85x 12.7) 6.85x 12.7) 6.85x 12.9)
Coil spring Green x 1 Green x 2 Light blue x 1 Light blue x 2 Light blue x 2 Orange x 1
identification
color
Spring constant
N/mm (IbsAn.) 22 (123) 22 (123) 24 (134) 24 (134) 24 (134) 24 (134)
Shock absorber
Type Hydraulic, cylindrical double acting type
Maximum length
mm (in.) 483 (19.02)
Compressed length
mm (in.) 330 (12.99)
Stroke mm (in.) 153 (6.02)
Damping force
[at 0.3 m/set.
(0.984 ft./sec.)l
Expansion
N (Ibs.) 1,000 (220)
Contraction
N (Ibs.) 3 0 0 ( 6 6 )
Wheel bearing
Type Double-row angular-contact ball bearing
0.D.xl.D. m m ( i n . ) 80x40 (3.15x1.57)
Drive shaft
Joint type
Outer B.J.“l
Inner T.J.“’
Drive shaft
Length mm (in.)
L.H. shaft 708 (27.9) 706 (27.8) 706 (27.8) 702 (27.6)
R.H. shaft 368 (14.5) 366 (14.4) 366 (14.4) 370 (14.5)
NOTE
*1: B.J.: Birfield joint
*2: T.J.: Tripod joint
FRONT SUSPENSION - Specifications
<AWD>
Items MiT Al-r
Suspension system McPherson strut with coil spring and compression rod type
Coil spring
Wire dia.xO.D.xfree length m m ( i n . ) 14.0x174.0x326.5 14.2x174.2x333.5
(.55x6.85x 12.9) (.56x6.86x13.1)
Coil spring identification color Pink x 1 Pink x 2
Spring constant N/mm (Ibs./in.) 26 (146) 26 (146)
Shock absorber
Type Hydraulic, cylindrical double acting type
Maximum length mm (in.) 489 (19.25)
Compressed length mm (in.) 340 (13.39)
Stroke mm (in.) 149 (5.87)
Damping force [at 0.3 m/set.
(0.984 ft./set.)]
Expansion N (Ibs.) 1,000 (220)
Contraction N (Ibs.) 3 0 0 ( 6 6 )
Wheel bearing
Type Double-row angular-contact ball bearing
0.D.xl.D. m m ( i n . ) 80x40 (3.15x1.57)
Drive shaft
Joint type
Outer B.J.“’
Inner T.J.“’
Drive shaft
Length mm (in.)
L.H. shaft 368 (14.5) 365 (14.4)
R.H. shaft 368 (14.5) 371 (14.6)
NOTE
*I: B.J.: Birfield joint
**: T.J.: Tripod joint
2-4 FRONT SUSPENSION - Specifications
SERVICE SPECIFICATIONS ;02CB-
Items <FWD> <AWD>

Vehicles with Vehicles with 2.0L DOHC Engine
1.8L Engine
Standard value
Camber 14’230’ 5’+30’ 10’+30’
Caster 2”20’ -t 30’ 2”24’ 3130’ 2”18’ f 30’
Toe-in m m ( i n . ) Of3 (Ok.12) Of3 (Ok .12) Of3 (Ok.12)
Protruding length of stabilizer bar
mounting bolt mm (in.) 16-18 (.63-.70) - -
Setting of T.J. boot length mm (in.)
L.H. 75+3 (2.95f.12) 80-+3 (3.15f.12) 85_+3 (3.35k.12)
R.H. 85f3 (3.35k.12) 80+3 (3.15k.12) 85f3 (3.35f.12)
Lower arm ball joint starting
torque N m (in.lbs.) 3-10 ( 2 6 - 8 7 ) 3- 10 (26-87) 3- 10 (26-87)
Stabilizer link ball joint starting
torque N m (inlbs.) - 1.7-3.2 (15-28) 1.7-3.2 (15-28)
Crossmember bushings projection
mm (in.)
Bushing A 7.2-10.2 (.28-.40) 7.2-10.2 (.28-.40) 7.2-10.2 (.28-.40)
Bushing B 6.5-9.5 (.26-.37) 6.5-9.5 (.26-.37) 6.5-9.5 (.26-.37)
Limit
Hub end play mm (in.) 0.2 (.008) or less
Wheel bearing starting torque
(Hub starting torque) N m (in.lbs.) 1.8 (16) or less
TORQUE SPECIFICATIONS NO2CG.
Items Nm ftlbs.
Drive shaft nut 200-260 144-188
Tie rod end ball joint 24-34 17-25
Knuckle to ball joint 60-72 43-52
Knuckle to strut assembly 1 IO-140 80-101
Strut top end nut 60-70 43-51
Strut uppermounting nut 40-50 29-39
Caliper assembly mounting bolt 80-100 58-72
Center bearing bracket 36-46 26-33
Front speed sensor bracket 9-14 7-10
Front toothed rotor 9-14 7-10
Stabilizer bar bracket to crossmember 30-42 22-30
Stabilizer link 35-45 25-33
Lower arm clamp to crossmember (nut) 35-47 25-34
Lower arm clamp to crossmember (bolt) 80-I 00 58-72
Lower arm to crossmember 100-120 72-87
Stay to crossmember 70-80 51-58
Front exhaust pipe to exhaust manifold
Turbo 40-60 29-43
Non-Turbo 30-40 22-29
Front exhaust pipe clamp 30-40 22-29
Crossmember to body 100-120 72-87
Front roll stopper bracket to centermember 40-50 29-36
FRONT SUSPENSION - Specifications 2-5
Items Nm ftlbs. I’, ‘,
Rear roll stopper bracket to centermember 40-50 29-36
Centermember installation bolts (front) 80-100 58-72
Centermember installation bolts (rear) 80-I 00 58-72
Joint assembly and gear box connecting bolt 15-20 II-14
Steering gear box assembly to return tube 12-18 9-13
Steering gear box assembly to pressure hose 12-18 9-13
Steering gear box assembly to crossmember 60-80 43-58
Pressure hose bracket to crossmember 9-14 7-10
Transfer installation bolt
<M/-T> 55-60 40-43
<AIT> 60-80 43-58
Gusset installation bolt 70-80 51-58
Left member installation bolt (front) 80-100 58-72
Left member installation bolt (rear) 70-80 51-58
Vo. 1 crossmember installation nut 80-100 58-72
qight member installation bolt (front) 80-100 58-72
?ight member installation bolt (rear) 70-80 51-58
+ont roll stopper to No. 1 crossmember 40-50 29-36
?ont roll stopper installation nut 50-65 36-47
Iront exhaust pipe to catalytic converter 40-60 29-43
‘rant exhaust pipe to hanger IO-15 7-11
‘-. LUBRICANTS NO2CD--
Items Specified lubricants Quantity
Outer surface of wheel bearing outer race MOPAR Multi-mileage Lubricant As required
Wheel bearing inner race Part No. 2525035 or equivalent
Oil seal lip
Strut insulator bearing
Lower arm ball joint
Stabilizer link
Inner dust cover MOPAR Multi-mileage Lubricant 7-10 g (.25-.35 oz.)

Part No. 2525035 or equivalent
Outer dust cover MOPAR Multi-mileage Lubricant 4 - 6 g (.14-.21 oz.)
Part No.2525035 or equivalent
B.J. boot grease Repair kit grease
<FWD>
Vehicles with 1.8L engine 95 g (3.4 oz.)
Vehicles with 2.0L DOHC engine 110 g (3.9 oz.)
<AWD> 95 g (3.4 oz.)
T.J. boot grease Repair kit grease

<FWD>
Vehicles with 1.8L engine 105 g (3.7 oz.)
Vehicles with 2.0L DOHC engine 120 g (4.2 oz.)
<AWD> 105 g (3.7 oz.)
Spider assembly Repair kit grease As required
NOTE
The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
2-6 FRONT SUSPENSION - Special Tools
SPECIAL TOOLS
Tool Number Name I Use
MB991004 Wheel alignment

gauge attachment
FRONT SUSPENSION - Special Tools 2-T
101 Number Name I Use
.-- M B990800 Ball joint remover and Installation of the dust cover
0 installer
Fi3
C-4628 Bearing installer Removal of wheel bearing
MB991 248 Inner shaft remover Removal of the inner shaft

or
MD998801
M 6990925 Bearing and oil seal Removal and installation of the center bearing
installer set Press-fitting of the dust seal
Brass bar
C
A
ar (one-touch type) Installer adapter
Tool number (MB9909251 O.D. mm (in.) Tool number (MB9909251 O.D. mm (in.)
MB990926 39 (1.54) A M B990933 63.5 (2.50)
M B990927 45 (1.77) M B990934 67.5 (2.66)

M 8990928 49.5 (1.95) M B990935 71.5 (2.81)
M B990929 51 (2.01) M B990936 75.5 (2.97)

MB990930 54 (2.13) M B990937 79 (3.11)
MB990931 57 (2.24) B M B990938 -
M 8990932 61 (2.40) 1 c 1 MB990939 -

2-8 FRONT SUSPENSION - Service Adjustment Procedures
SERVICE ADJUSTMENT PROCEDURES

HUB END PLAY INSPECTION NO2FAAB -
- - ’
1. Jack up the vehicle and remove the front wheels.

2. Remove the disc brake caliper and suspend it with a wire.
(Refer to GROUP 5-Service Adjustment Procedures.)
3. Attach a dial indicator as shown in the illustration, and then
measure the axial play while moving the hub back and
forth.
Limit : 0.2 mm (.008 in.) or less
NOTE
Secure the brake disc and hub by the wheel nut so that the
brake disc won’t come off the hub.
4. If axial play exceeds the limit, disassemble and check parts.
FRONT WHEEL ALIGNMENT NOZFBAQ
NOTE
The front suspension assembly must be free of worn, loose or
damaged parts prior to measurement of front wheel align- A
ments. --l
Measure wheel alignment by using the special tool.
CAMBER AND CASTER

Standard value :
<1.8L> <2.0L>
FWD A W D
Camber 14’+ 30’ 5’k30 10’f 30
Caster 250 + 30’ 2”24’ + 30’ 29 8’ f 30
Camber and caster are pre-set at the factory and cannot be

adjusted.
NOTE
If camber and caster are not within specifications, replace bent
or damaged parts.
TOE-IN
Standard value : Of3 mm (Of.12 in.)
1. Adjust the toe-in by undoing the clips and turning the left
and right tie rod turnbuckles by the same amount (in -
opposite directions).
2. The toe will move out as the left turnbuckle is turned - ,’
toward the front of the vehicle and the right turnbuckle is
turned toward the rear of the vehicle.
FRONT SUSPENSION - s ervice Adjustment Procedures/Hub and Knuckle 2-9
3. For each half turn of the left and right tie rods, the toe-in will
be adjusted by 6 mm (24 in.).
4. After making the adjustments, use a turning radius gauge
to confirm that the steering wheel turning angle is within
the standard value range. (Refer to GROUP 19-Service
Adjustment Procedures.)
WHEEL BEARING ADJUSTMENT N02FCM
Bearing preload is pre-set to the specified value by design and

therefore can not be adjusted.
HUB AND KNUCKLE

REMOVAL AND INSTALLATION NOZIA-
110-140 Nm
80-101 ft.lbs.
/
24-34 Nm
80-106 Nm ’
/ 58-72 ft.lbs.
7- 10 ft.lbs.
Removal steps
5 60->2 Nm
l * 1. Cotter pin 43-52 ft.lbs.
+w ~~ 2. Drive shaft nut
l + 3. Washer -70-260 Nm
+I) 4. Front speed sensor connection .A-188 ft.lbs.
<Vehicles with A B S: >
(Refer to GROUP 5-Speed Sensor.)
5. Caliper assembly 11Ams4
4*
6. Brake disc
7. Self locking nut
+e l + 8. Connection for lower arm ball joint
9. Cotter pin
10. ivkeverse the removal procedures to reinstall.
:: 11. Drive shaft (2) +* : Refer to “Service Points of Removql”.
12. Front strut mounting bolt (3) l + : Refer to “Service Points of Installation”.
13. Hub and knuckle (4) a : Non-reusable parts
z-10 FRONT SUSPENSION - Hub and Knuckle
SERVICE POINTS OF REMOVAL NOZIBAG
2. REMOVAL OF DRIVE SHAFT NUT 6-e

Loosen the drive shaft nut while the vehicle is on the floor _ ,’
with the brakes applied.
Front speed 4. DISCONNECTION OF FRONT SPEED SENSOR

sensor Remove the mounting bolts which hold the speed sensor
bracket to the knuckle, and then remove the speed sensor.
Caution
Be careful when handling the pole piece at the tip of
the speed sensor and the toothed edge of the rotor so
as not to damage them by striking against other parts.
5. REMOVAL OF CALIPER ASSEMBLY
Pole piece Remove the caliper assembly and suspend it with wires.
,4mx‘l4
8. DISCONNECTION OF LOWER ARM BALL JOINT

Using the special tool, disconnect the lower arm ball joint
from the knuckle.
Caution ,*
1. Be sure to tie the cord of the special tool to the 1
nearby part.
2. Loose the nut but do not remove it.
IO. DISCONNECTION OF TIE ROD END

Using the special tool, disconnect the tie rod end from the
knuckle.
Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
1 11. REMOVAL OF DRIVE SHAFT

J& (1) Using the suitable tool to push out the drive shaft from
the front hub.
FRONT SUSPENSION - Hub and Knuckle 2-11
(2) <M/T, Non-Turbo A/T>
Insert a pry bar between the transaxle case and the
drive shaft, and then pry the drive shaft from the
transaxle.
Caution
1. Do not pull on the drive shaft; doing so will
damage the T.J.; be sure to use the pry bar.
2. Do not insert the pry bar so deep as the damage
the oil seal.
Transaxle
Pry bar <Turbo A/T>
llE5&
Refer to P.2-23.
INSPECTION NO2lCAD
l Check the hub for cracks and spline for wear.

l Check the oil seal for damage.
l Check the knuckle for cracks.
l Check for defective bearing.
NOTE
If the meshing of the wheel bearing outer race and the
knuckle, or of the wheel bearing inner race and the hub, is
loose, replace the bearing or damaged parts.
SERVICE POINTS OF INSTALLATION NOZIDAD
8. INSTALLATION OF LOWER ARM BALL JOINT

Lower the vehicle to the ground and tighten the knuckle to
the lower arm ball joint connecting bolt.
3. INSTALLATION OF WASHER/S. DRIVE SHAFT NUT/l.

er pin
COTTER PIN
(1) Be sure to install the washer and wheel bearing nut in
the specified direction.
(2) After installing the wheel, lower the vehicle to the
ground and finally tighten the wheel bearing nut.
(3) If the position of the cotter pin holes does not match,
tighten the nut up to 260 Nm (188 ftlbs.) in maximum.
Hub
(4) Install the cotter pin in the first matching holes and
bend it securely.
2-12 FRONT SUSPENSION - Hub and Knuckle
N02lE--
DISASSEMBLY AND REASSEMBLY
llA0353
Disassembly steps Reassembly steps

1. Front hub 8. Front toothed rotor <A B S>
:t 2. Oil seal (drive shaft side) (Refer to GROUP 5-Wheel Speed
3. Snap ring Sensor.)
4. Oil seal (hub side) 7. Knuckle
5. Wheel bearing 6. Dust shield
6. Dust shield ‘.++ 5. Wheel bearing
7. Knuckle l + 4. Oil seal (hub side)
8. Front toothed rotor <A B S> ’ 3. Snap ring
(Refer to GROUP 5-Wheel Speed l + 1. Front hub
Sensor.) l * Adjustment of wheel bearing starting
torque
~~ 2. Oil seal (drive shaft side)
NOTE
(1) +e : Refer to “Service Points of Disassembly”.
(2) l + : Refer to “Service Points of Reassembly”.
(3) m : Non-reusable parts
- SERVICE POINTS OF DISASSEMBLY NO2lFAO
1. REMOVAL OF FRONT HUB

(1) Attach the special tools to the knuckle and front hub.
MB991 056 or (2) Secure the knuckle in a vise.
(3) Tighten the nut of the special tool and remove the front
hub from the knuckle.
Caution
1. Be sure to use the special tools.
2. If the front hub and knuckle are disassembled by
striking them with a hammer, the bearing will
11uo050 be damaged.
FRONT SUSPENSION - Hub and Knuckle 2-13
2. REMOVAL OF OIL SEAL (DRIVE SHAFT SIDE)
Remove the oil seal (drive shaft side) from the knuckle.
5. REMOVAL OF WHEEL BEARING

(1 ) Crush the oil seal in two places so that the tabs of the
special tool will be caught on the wheel bearing inner
race.
llA0281
(2) Remove the wheel bearing inner race from the front
hub by using the suitable puller.
NOTE
Be careful that the front hub will not fall down at the
wheel bearing inner race (outer side) removed from the
hub.
Snar,
(3) Remove the snap ring from the knuckle.
(4) Remove the bearing by using the special tools.
Caution
Removal is easier if the outer side inner race
removed from the hub is placed on the bearing and
the wheel bearing is then removed.
MB991 056 or
MB991 001 ! 12A0554
INSPECTION NOZffiAkh
0 Check the front hub and brake disc mounting surfaces for
galling and contamination.
l Check the knuckle inner surface for galling and cracks.
0 Check for defective bearing.
2-14 FRONT SUSPENSION - Hub and Knuckle
SERVICE POINTS OF REASSEMBLY NOZIHAN
5. INSTALLATION OF WHEEL BEARING A

(1) Fill the wheel bearing with multipurpose grease. -
(2) Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
Grease: MOPAR Multi-mileage Lubricant
llR0032
(3) With the wheel bearing inner race removed, press-in

the bearing by using the special tools.
(4) Install the wheel bearing inner race to the wheel
bearing.
4. INSTALLATION OF OIL SEAL (HUB SIDE)

(1) Drive the oil seal (hub side) into the knuckle by using
the soecial tools until it is flush with the knuckle end
surface. A
(2) Apply multipurpose grease to the lip of the oil seal and
to the surfaces of the oil seal which contact the front
hub.
1. INSTALLATION OF FRONT HUB

(1) Use the special tool to mount the front hub assembly
onto the knuckle.
(2) Tighten the nut of the special tool to 200-260 Nm
(144-188 ft.lbs.).
(3) Rotate the front hub assembly in order to seat the
bearing.
l ADJUSTMENT OF WHEEL BEARING STARTING

TORQUE
(1) Measure the wheel bearing starting torque (hub
starting torque) by using the special tools.
Limit: 1.8 Nm (16 in.lbs.) or less ic
‘-
NOTE
The starting torque must be within the limit and, in
addition, the bearing must not feel rough when
rotated.
llK012
FRONT SUSPENSION - Hub and Knuckle/Drive Shaft 245
(2) Measure to determine whether the end play of the hub

is within the specified limit or not.
Limit: 0.2 mm (.008 in.) or less
(3) If the starting torque and hub end play are not within the
limit range while the nut is tightened to 200-260 Nm
(144- 188 ftlbs.), the bearing, hub and/or knuckle have
probably not been installed correctly. Repeat the
disassembly and assembly procedure.
2. INSTALLATION OF OIL SEAL (DRIVE SHAFT SIDE)

M B990985 Drive the oil seal (drive shaft side) into the knuckle until it
contacts the snap ring.
Apply multipurpose grease to the lip of the oil seal.
llR0066
DRIVE SHAFT <FWD> NOPClA-A
The T.J.-B.J. type is used for FWD all models.
PARTS DISTINCTION
Boots and boot bands can be distinguished by the
indicated part number as below.
T.J-B.J TYPE
T.J. boot band T.J. boot Boot band (small) B.J. boot B.J. boot band
Identification Identification Identification
Part shapes and location location location
part identification
number location
Identification Identification
location location
llK033 llR0156 llK033 llK033 llK03:
1800 20-I 10 17-261 #TJ87. 20- 146 17-249#BJ87L 20-I 1 3

2000 20-12 17-55#TJ92 20-111 17-31 #BJ92L 20-75
2-16 FRONT SUSPENSION - Drive Shaft
REMOVAL AND INSTALLATION
q 4 sm 24-34 N m
\ I 17-25 ft.lbs.
/ 200-260 Nm
I 144-168 ftlbs.
-7
Removal steps
l * 1. Cotter pin
4e l + 2. Drive shaft nut
l 4 3. Washer llA0099
4. Self locking nut
+e l + 5. Connection for lower arm ball joint NOTE
6. Cotter pin (1) Reverse the removal procedures to reinstall.
** 7. Connection for tie rod end (2) 4* : Refer to “Service Points of Removal”.
l * 8. Drive shaft (3) l 4 : Refer to “Service Points of Installation”
9. Circlip (4) q : Non-reusable parts
SERVICE POINTS OF REMOVAL NOZOBAL
2. REMOVAL OF DRIVE SHAFT NUT

Loosen the drive shaft nut while the vehicle is on the floor
with the brakes applied.
from the knuckle.
Caution
12130255
nearby part.
7. DISCONNECTION OF TIE ROD END
knuckle.
Caution
w nearby part.
llLOO15
FRONT SUSPENSION - Drive Shaft 247
8. REMOVAL OF DRIVE SHAFT .’
(1) Use the suitable tool to push out the drive shaft from
the front hub.
(2) <M/T, Non-Turbo A/T>

transaxle.
Caution
2. Do not insert the pry bar so deep as the damage
the oil seal.
Pry bar
<Turbo A/T>
13E526
Refer to P.2-23.
Caution
Do not apply the vehicle weight to the wheel bearing
while the drive shaft is disconnected. If the vehicle
weight must unavoidably be applied (because of
vehicle movement or some other reason), use the
special tool to hold the wheel bearing, as shown in the
figure.
12RO426
INSPECTION N62CXAC
l Check the drive shaft boot for damage or deterioration.

l Check the ball joints for wear or operating condition.
l Check the spline part for wear or damage.
SERVICE POINTS OF INSTALLATION N62aoAJ

5. INSTALLATION OF LOWER ARM BALL JOINT
Lower the vehicle to the ground and tighten the knuckle to
the lower arm ball joint connecting nut.
3. INSTALLATlON OF WASHER/2. DRIVE SHAFT NUT/l.
COTTER PIN
Cotter pin (1) Be sure to install the washer and wheel bearing nut in
/ the specified direction.
(2) After installing the wheel, lower the vehicle to the
ground and finally tighten the wheel bearing nut.
(3) If the position of the cotter pin holes does not match,
tighten the nut up to 260 Nm (188 ft.lbs.) in maximum.
(4) Install the cotter pin in the first matching holes and
/ bend it securely.
Hub llR0015
Z-18 FRONT SUSPENSION - Drive Shaft
NOZOE-A
llAOf35
Disassembly steps
l + 1. T.J. boot band
W 2. Boot band (small)
e4 3. T.J. case
4* 4. Snap ring
4I) l + 5. Spider assembly
4ee4 6. T.J. boot NOTE
7. B.J. boot band (I) Reverse the disassembly procedures to reassemble.
8. Boot band (small) (2) 4+ : Refer to “Service Points of Disassembly”.
4ee4 9. B.J. boot (3) l : Refer to “Service Points of Reassembly”.
10. B.J. assembly (4) q : Non-reusable parts
11. Dust cover
12. Circlip
2 6 1
llR0169
llR0166
T.J. Boot kit T.J. Joint kit
llA0128
B.J. Boot kit B.J. Joint and shaft kit

-I
FRONT SUSPENSION - Drive Shaft 249'
SERVICE POINTS OF DISASSEMBLY NO2ClFDC
4. REMOVAL OF SNAP RING/S. SPIDER ASSEMBLY

(1) Remove the snap ring from the drive shaft with the
snap ring pliers.
(2) Take out the spider assembly from the drive shaft.
(3) Clean the spider assembly.
Caution
1. Do not disassemble the spider assembly.
2. If the T.J. of the drive shaft assembly is bent, the
I llE561 I joint may be damaged. Use care in handling the
drive shaft.
3. The drive shaft joint use special grease. Do not
add another type of grease.
6. REMOVAL OF T.J. BOOT/g. B.J. BOOT

(1 ) Wrap vinyl tape around the spline part on the T.J. side
of the drive shaft so that the T.J. and B.J. boots are not
damaged when they are removed.
(2 ‘) Withdraw the T.J. and B.J. boots from the drive shaft.
Caution
Do not disassemble the B.J.
Distinguish between B.J. boot and T.J. boot parts.
INSPECTION NO2QGDC
l Check the drive shaft for damage, bending or corrosion.

l Check the drive shaft spline part for wear or damage.
l Check for entry of water and/or foreign material into B.J.
l Check the spider assembly for roller rotation, wear or
corrosion.
l Check the groove inside T.J. case for wear or corrosion.
l Check the boots for deterioration, damage or cracking.
SERVICE POINTS OF REASSEMBLY NMOHDD
9. INSTALLATION OF B.J. BOOT/6. T.J. BOOT

(1) Wrap vinyl tape around the spline part on the drive
shaft, and then install the B.J. boot and T.J. boot, in that
order.
Caution
Distinguish between B.J. boot and T.J. boot parts
according to the section “Parts Distinction”, and be
sure to assemble them correctly.
FRONT SUSPENSION - Drive Shaft
(2) Fill the inside of the B.J. and B.J., boot with the
specified grease.
Wil
Specified grease: Repair kit grease
95 g (3.4 oz.) *I, 110 g (3.9 oz.)** -
NOTE
The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
*I: <Vehicles with 1.8L engine>
*2: <Vehicles with 2.0L DOHC engine>
I llA0127 (3) Secure the boot bands.
Caution
The boot bands should be tightened with the drive
shaft at a 0” joint angle.
5. APPLICATION OF GREASE TO SPIDER ASSEMBLY

Apply the specified grease furnished in the repair kit to the
spider assembly.
3. APPLICATION OF GREASE TO T.J. CASE

llE560
Fill the specified grease furnished in the repair kit to the T.J.
case.
Grease
105 g (3.7 oz.) *‘I, 120 g (4.2 oz.)**
NOTE A
The grease in the repair kit should be divided in half for use, -
respectively, at the joint and inside the boot.
*I: <Vehicles with 1.8L engine>
*2: <Vehicles with 2.0L DOHC engine>
llE563
2. INSTALLATION OF BOOT BAND (SMALL)/ 1. T.J.

BOOT BAND
Set the T.J. boot bands at the specified distance in order to
adjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot band securely.
Standard value:
LH RH
<l.SL> 75+3 mm 8523 mm
(2.95f .I2 in.) (3.35 f .I2 in.)
llE559 <2.0L> 80f3 mm SO+3 mm
(3.15f.12 in.) (3.15+ .I2 in.)
FRONT SUSPENSION - Drive Shaft
DRIVE SHAFT <AWD> NOZOA-6
T.J.-B.J. type drive shaft is used. The left side drive

shaft has an inner shaft and center bearing so that
the left and right side drive shafts are same length.
PARTS DISTINCTION
Boots and boot bands can be distinguished by the
T.J. boot band T.J. boot Boot band (small) B.J. boot B.J. boot band
Identification Identification Identification
Part shapes and location location location
part identification
number location
u
Identification
location Identification 6
location
llK033 llRO,SB llK033 llK033 llKO33
20-I 10 17-261 #TJ87 20-146 17-249#BJ87L 20-I 1 3

Pre-removal Operation Pre-installation Operation

l Removal of the Under Cover l installation of the Under Cover
60-72 Nm
43-52 ftlbs. 60-72 Nm
I 43-52 ftlbs.
24-34 N m
17-25 ft.lbs.
200-260 irn
145-188 ft.lbs.
I
Y
36-46 N m
26-33 ft.lbs.
llAO322
Removal steps
I. Cotter pin
+I) l * 2. Drive shaft nut
4* 3. Lower arm ball joint connection
4. Cotter pin
l * 5. Tie rod end connection
6. Center bearing bracket installation bolt NOTE
7. Spacer (Vehicles without air conditioner) (1) Reverse the removal procedures to reinstall.
8. Drive shaft and inner shaft assembly (L.H.) (2) 4* : Refer to “Service Points of Removal”.
:: 9. Drive shaft (R.H.) (3) l + : Refer to “Service Points of Installation”.
10. Circlip (4) m : Non-reusable parts
SERVICE POINTS OF REMOVAL NOZQBAT
2. REMOVAL OF DRIVE SHAFT NUT/3. LOWER ARM

BALL JOINT/5. TIE ROD END
Refer to P.2-16.
8. REMOVAL OF DRIVE SHAFT AND INNER SHAFT
ASSEMBLY (L.H.)/9. DRIVE SHAFT (R.H.)
(1) Use the suitable tools to push out the drive shaft and
inner shaft assembly (L.H.) or the drive shaft (R.H.) from
the front hub.
1 lA0266 1
FRONT SUSPENSION - Drive Shaft 2-23
(2) Remove the drive shaft and inner shaft asSembly (L.H..)
from the transaxle by lightly tapping the T.J. case with a
plastic hammer, etc.
(3) The drive shaft (R.H.) is removed as described below.

<MIT>
transaxle.
Caution
1. Do not pull out the drive shaft; doing so will
2. Do not insert the pry bar so deep as to damage
the oil seal.
llE526
<A/T>
Insert a pry bar at the projection part and remove the
drive shaft (R.H.) from the transaxle.
Caution
Do not pull out the drive shaft; doing so will
INSPECTION N02QCAE
l Check the drive shaft boot for damage or deterioration.

l Check the ball joints for wear or operating condition.
l Check the spline part for wear or damage.
l Check the operation of the center bearing.
SERVICE POINTS OF INSTALLATION NOZQDAQ
2. INSTALLATION OF DRIVE SHAFT NUT

Refer to P.2-17.
DISASSEMBLY AND REASSEMBLY NOZQE-B
T.J. boot repair kit
d-
‘Pr
12
45,3 ;c
llA0316
!'F?
14 - 151 9 2
0 11AOH8
T.J. kit
B.J. boot repair kit B.J. kit Bearing dust seal kit
Disassembly steps
1. T.J. boot band
2. Boot band (small)
3. T.J. case and inner shaft assembly
4. T.J. case llA0317
5. Seal plate 16. B.J. boot band
6. Inner shaft 17. Boot band (small) Bracket assembly kit
7. Bracket assembly +I) l 4 18. B.J. boot
8. Outer dust seal 19. B.J. assembly
9. Inner dust seal 20. Dust cover
10. Center bearing
11. Center bearing bracket
12. Circlip FJ)TEeverse the disassembly procedures to reassembly.
4* 13. Snap ring (2) +e : Refer to “Service Points of Disassembly”.
+e e+ 14. Spider assembly (3) l + : Refer to “Service Points of Reassembly”.
4I) l 4 15. T.J. boot (4) m : Non-reusable parts
T.J. case \ \ t/P- SERVICE POINTS OF DISASSEMBLY NOZOFED
I I I
6. REMOVAL OF INNER SHAFT
(1) Using the special tool, remove the inner shaft assem-
bly, together with the seal plate, from the T.J. case.
(2) Use the suitable puller to remove the inner shaft from
the center bearing bracket.
llA0092
10. REMOVAL OF CENTER BEARING

-/ MB990938 Use the special tools to remove the center bearing from the
center bearing bracket.
ix
13. REMOVAL OF SNAP RING/l4. SPIDER ASSEMBLY

(1) Remove the snap ring from the drive shaft with the
snap ring pliers.
(2) Take out the spider assembly from the drive shaft.
(3) Clean the spider assembly.
Caution
1. Do not disassemble the spider assembly.
2. If the T.J. of the drive shaft assembly is bent, the
joint may be damaged. Use care in handling the
drive shaft.
11E561
3. The drive shaft joint use special grease. Do not
add another type of grease.
15. REMOVAL OF T.J. BOOT/l8. B.J. BOOT
(1) Wrap vinyl tape around the spline part on the T.J. side
of the drive shaft so that the T.J. and B.J. boots are not
damaged when they are removed.
(2) Withdraw the T.J. and B.J. boots from the drive shaft.
Caution
Do not disassemble the B.J.
Distinguish between B.J. boot and T.J. boot parts.
llYO97
INSPECTION N02QGEB
Check the drive shaft for damage, bending or corrosion.

Check the inner shaft for damage, bending or corrosion. -
Check the drive shaft spline part for wear or damage. =-
Check the inner shaft spline for wear or damage.
Check for entry of water and/or foreign material into B-J..
Check the spider assembly for roller rotation, wear or
corrosion.
0 Check the groove inside T.J. case for wear of corrosion.
0 Check the boots for deterioration, damage or cracking.
0 Check the center bearing for seizure, discoloration or
roughness of rolling surface.
0 Check the dust cover for damage or deterioration.
SERVICE POINTS OF REASSEMBLY NOZQHEEa
18, INSTALLATION OF B.J. BOOT/15. T.J. BOOT

(1) Wrap vinyl tape around the spline part on the drive
shaft, and then install the B.J. boot and T.J. boot, in that .*
order.
Caution
Distinguish between B.J. boot and T.J. boot parts
according to the section “Parts Distinction”, and be
sure to assemble them correctly.
(2) Fill the inside of the B.J. and B.J. boot with the
specified grease.
Specified grease: Repair kit grease 95 g (3.4 OZ.)
NOTE
(3) Secure the boot bands.
Caution
The boot bands should be tightened with the drive
shaft at a 0” break angle.
14.APPLlCATlON OF GREASE TO SPIDER ASSEMBLY

Apply the specified grease furnished in the repair kit to the
spider assembly.
llE560
10. INSTALLATION OF CENTER BEARING
(1) Apply multipurpose grease to the center bearing and
inside the center bearing bracket.
llAOO91
(2) Use the special tools to press-fit the center bearing into
M B990938 the center bearing bracket.
11L0010
Inner dust seal Outer dust seal 9./8. INSTALLATION OF DUST SEALS
(1) Apply multipurpose grease to the rear surfaces of all
dust seals.
Inner dust seal 7-10 g (.25-.35 oz)
Outer dust seal 4 - 6 g (.14-.21 oz)
llLOO12
(2) Use the special tools to install the dust seal so that its
nner dust seal, p MB990938 surface runs even with that of the center bearing
bracket.
(3) Apply multipurpose grease to the lip of each dust seal.
Grease: MOPAR Multi-mi!eage Lubricant
11 LOO09
Outer dust seal NOTE

When applying grease, make sure that it does not adhere to
anything outside the lip.
6. INSTALLATION OF INNER SHAFT
Use a pipe to hold the inner race of the center bearing and “4
Inner shaft force the inner shaft into place. .a
llA0083
3. INSTALLATION OF T.J. CASE AND INNER SHAFT

1 ASSEMBLY
(1) Apply multipurpose grease to the inner shaft spline,
then press fit it into the T.J. case.
(2) Using the special tools, press the seal plate into the T.J.
, MB990938
case.
T.J. case.
3%Q ilD998801
(3) Fill the specified grease furnished in the repair kit to the
T.J. case.
Specified grease: Repair kit grease 105 g (3.7 oz.1
NOTE
Caution
The drive shaft joint use special grease. Do not add
another type of grease.
r 2. INSTALLATION OF BOOT BAND (SMALL)/ 1. T.J.

BOOT BAND
Set the T.J. boot bands at the specified distance in order to
adjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot band securely. e
Standard value: 85f3 mm (3.35+ .12 in.)
I HA0087
FRONT SUSPENSION - Strut Assembly
STRUT ASSEMBLY
40-50 Nm
N02lA-
- REMOVAL AND INSTALLATION 29-36 ft.lbs.\4
1.
Removal steps
4* 1. Brake hose and tube bracket
2. Front speed sensor cramp <Vehicles with 110-140 Nm
.-
ABS> 80-101 ft.lbs.
4* 3. Strut lower mounting bolt
4. Strut upper mounting nut
e+ 5. Strut assembly
!rEeverse the removal procedures to reinstall.

(2) **: Refer to “Service Points of Removal”.
(3) l 4 : Refer to “Service Points of Installation”. 1110355
SERVICE POINTS OF REMOVAL NO2LBAF
1. REMOVAL OF BRAKE HOSE AND TUBE BRACKET

Do not pry the brake hose and tube clamp away when
removing it.
3. REMOVAL OF STRUT LOWER MOUNTING BOLT

After the union between the strut and the knuckle has been
removed, jack up the lower arm, attaching the brake hose,
tube and drive shaft to the knuckle with wire so that they
will not be pulled on.
INSPECTION NO2LCAB
l Check for oil leaks from the strut assembly.

l Check the strut assembly shock absorber for damage or
deformation.
2-30 FRONT SUSPENSION - Strut Assembly
SERVICE POINTS OF INSTALLATION NOZLDAG
Y---i-- Strut 5. INSTALLATION OF STRUT ASSEMBLY

insulator
Install the strut assembly so that the strut insulator faces in 7
the direction indicated in the illustration.
NOTE
Be sure to confirm that the direction is correct, because
there will be a deviation of the wheel alignment if it is not.
Front
a 12A0521
N02LE-
60-70 Nm
43-51 ft.lbs.~d/-2~
- 6
- 7
12A0528
Disassembly steps
I, Dust cover
+e I)+ 2. Self-locking nut
3. Strut insulator
l * 4. Spring seat, upper
5. Spring pad, upper NOTE
l + 6. Bump rubber (I) Reverse the disassembly procedures to reassemble.
l + 7. Dust cover (2) +e : Refer to “Service Points of Disassembly”
8. Coil spring (3) e+ : Refer to “Service Points of Reassembly”
9. Strut assembly (4) m : Non-reusable parts
FRONT SUSPENSION - Strut Assembly
SERVICE POINTS OF DISASSEMBLY NO2LFAI
2. REMOVAL OF SELF-LOCKING NUT

(1) Holding the spring upper seat with the special tool,
loosen the self-locking nut.
Caution
The self-locking nut should be loosened ,only, not
removed.
(2) Using the special tools, compress the coil spring, and
then remove the self-locking nut.
NOTE
Install the special tools evenly, and so that the
maximum length will be attained within the installation
range.
MB991237 -
12l.0254
INSPECTION NOZLGAE
l Check the strut insulator bearing for wear or rust.

l Check the rubber parts for damage or deterioration.
0 Check the spring for deformation, deterioration or dam-
age.
l Check the shock absorber for deformation.
Strut insulator bearing

12A0523
SERVICE POINTS OF REASSEMBLY NO2LHAK
7. INSTALLATION OF DUST COVER/G. BUMP RUBBER

Join the dust cover and bump rubber.
Bu’mp rubber Dust Gover

12LOO32
-
2-32 FRONT SUSPENSION - Strut Assemblv
4. INSTALLATION OF SPRING UPPER SEAT ASSEMBLY
(1) Assemble the spring upper seat to the piston rod,
fitting the notch in the rod to the shaped hole in spring -
seat. L .I
(2) Line up the holes in the strut assembly spring lower

seat with the hole in the spring upper seat.
NOTE
The job is easily accomplished with a pipe [ralO mm x
300 mm (0.4 in. x 11.8 in.)].
2. INSTALLATON OF SELF-LOCKING NUT

(1) With the coil spring held compressed by the special
tools (MB991 237 and MB991 238), provisionally tighten
the self-locking nut.
(2) Correctly align both ends of the coil spring with the ?
grooves in the spring seat, and then loosen the special
tools (MB991237 and MB991 238).
(3) Using the special tool, tighten the strut insulator at the
specified torque.
12LO251
(4) Apply multipurpose grease to the bearing part of the

strut, insulator, and install the insulator cap.
Insulator rubber
Caution
When applying the grease, take care that grease
does not adhere to the insulator’s rubber part.
12A0522,
FRONT SUSPENSION - Lower Arm 2h33
LOWER ARM
--” REMOVAL AND INSTALLATION NOZNA-
<Models equipped with the rubber bushing type of stabilizer>
100 -12/o Nm*

72- .87 ft.lbs.*
12 !!
80-100 Nm*
58-72 ft.lbs.*
\ 100-120 Nm
72-87 ft.lbs.
12A0527
Removal step
H 1. Stabilizer bar mounting nut
2. Stabilizer bar mounting bolt
3.
- Joint cups and bushing
4. Collar
+* 7. Self-locking nut NOTE
8. Lower arm mounting nut and bolt (I) Reverse the removal procedures to reinstall.
(2) 4+: Refer to “Service Points of Removal”.
9. Self-locking nut (3) w : Refer to “Service Points of Installation”.
In PIP.-..
I “. b,cdl, l)J
14.; m : Non-reusable parts
1 I. Lower arm * : Indicates parts whrch should be temporarily tight-
12. Stopper ened, and then fully tightened with the vehicle in
13. Ball joint dust cover the unladen condition.
2-34 FRONT SUSPENSION - Lower Arm
<Models equipped with the pillow-ball type of stabilizer>
35-45 Nm
25-33 ftlbs.
\ ,/- +-
100-120 Nm*
72-87 ft.lbs.*
35-45 Nm’ 35-47 Nm

25-33 ft.lbs.
_ -
/
80-100 Nm* 12A0526
58-72 ft.lbs.*
100-120 Nm
72-87 ft.lbs.
Removal step
+e l 4 5. Stabilizer link mounting nut
6. Stabilizer link
l * 7. Self-locking nut
NOTE
8. Lower arm mounting nut and bolt (1) Reverse the removal procedures to reinstall.
9. Self-locking nut (2) +e : Refer to “Service Points of Removal”.
10. Clamp (3) l + : Refer to “Service Points of Installation”.
1 I. Lower arm I# m : Non-reusable parts
12. Stopper * : Indicates parts which should be temporarily tight-
13. Ball joint dust cover ened, and then fully tightened with the vehicle In
the unladen condition.
FRONT SUSPENSION - Lower Arm 2-35
SERVICE POINTS OF REMOVAL NOZNSAL
5. REMOVAL OF STABILIZER LINK MOUNTING NUTS

Using a wrench or similar tool to secure the ball studs at
both ends of the stabilizer link, remove the mounting nuts.

from the knuckle.
Caution
nearby part.
2. Loosen the nut but do not remove it.
INSPECTION NOZNCAE
l Check the bushing for wear and deterioration.

l Check the lower arm for bend or breakage.
l Check the clamp for deterioration or damage.
l Check the ball joint dust cover for cracks.
l Check all bolts for condition and straightness.
CHECKING OF BALL JOINT FOR STARTING TORQUE

(1) If a crack is noted in the dust cover, replace it, adding
grease.
(2) Deflect side to side the ball joint stud several times.
(3) Mount two nuts on the ball joint, and then measure the ball
joint starting torque.
Standard value: 3-10 Nm (26-87 in.lbs.)
(4) If the starting torque exceeds the upper limit of standard
value, replace the lower arm assembly.
(5) Even if the starting torque is below the lower limit of the
standard value, the ball joint may be reused unless it has
12UOO18 drag and excessive play.
2-36 FRONT SUSPENSION - Lower Arm
Lips BALL JOINT DUST COVER REPLACEMENT NOZNEAF

/I
(1) Remove the dust cover.
(2) Apply multipurpose grease to the lip and inside of the dust 7
Dust
cover
cover.
12R0487
(3) Drive in the dust cover with special tool until it is fully
seated.
SERVICE POINTS OF INSTALLATION NOZNFAL
5. INSTALLATION OF STABILIZER LINK MOUNTING

NUTS
Using a wrench or similar tool to secure the ball studs at T
both ends of the stabilizer link, tighten the mounting nuts.
1. INSTALLATION OF STABILIZER BAR MOUNTING NUT

Tighten the nut on the stabilizer bar bolt to the specified
distance.
Standard value:
Protruding length of stabilizer bar .M”
mounting bolt 16-18 mm (.63-.70 in.) .
FRONT SUSPENSION - Stabilizer Bar 2-37
STABILIZER BAR <FWD>
NO2TAA
-I*_ REMOVAL AND INSTALLATION
<Rubber bushing type>
Removal steps
1. Self-locking nut
4* 2. Front exhaust pipe
z’ gitket 30-40 Nm
5: Center member rear installation bolt 22-29 ft.lbs.
l 4 6. Stabilizer bar mounting nut
7. Stabilizer bar mounting bolt
8. J&~;~cups and bushing
9.
Stabilizer bar bracket mounting bolt
l4 1:: Sg:asAi;r bar bracket 22-29 ft.lbs. 12A0555
14. 2
.. 4* 15. Stabilizer bar
NOTE
(I) Reverse the removal procedures to reinstall.
(2) 4* : Refer to “Service Points of Removal”.
(3) l 4 : Refer to “Service Points of Installation”.
(4) q : Non-reusable parts
12*0229
2-38 FRONT SUSPENSION - Stabilizer Bar
<Pillow-ball type>
<Turbo>
<Non-Turbo>
52-72 klbs.
40-60 Nm
29-43 fLlb
Removal steps
1, Self-locking nut 30-:O Nm V 2
4* 2. Front exhaust pipe 22-29 ftlbs. 30-40 Nm
3. Gasket 22-29 ft.lbs.
4. Stay
5. Center member rear installation bolt
4e l 4 10. Stabilizer link mounting nut
II. Stabilizer link
12. Stabilizer bar bracket mounting bolt
l 4 13. Stabilizer bar bracket
14. Bushing
4* 15. Stabilizer bar
c- r
35-45
2 5 - 3 3 ft.lbs. 10
NOTE
(I) Reverse the removal procedures to reinstall. 12A0228
(2) 4e : Refer to “Service Points of Removal”.
(3) l + : Refer to “Service Points of Installation”
(4) m : N o n - r e u s a b l e p a r t s
SERVICE POINTS OF REMOVAL NOZTBAFa
2. REMOVAL OF FRONT EXHAUST PIPE

After disconnection of the front exhaust pipe assembly and
the exhaust manifold, use wire, etc. to hang the front
exhaust pipe down.
Caution
There is danger of damage to the interior if the flexible
joint is bent very much. Do not bend it more than
shown in the figure.
10. REMOVAL OF STABILIZER LINK MOUNTING NUT

both ends of the stabilizer link, remove the mounting nuts.
15. REMOVAL OF STABILIZER BAR

(1) Pull out both ends of the stabilizer bar to the rear of the
drive shaft.
(2) Move the right stabilizer bar until the end of the
stabilizer bar clears the lower arm.
(3) With the end that has cleared the lower arm, pull out
the stabilizer bar diagonally.
Z-40 FRONT SUSPENSION - Stabilizer Bar
INSPECTION NO2TCAF
l Check the bushing for wear and deterioration. rt

l Check the stabilizer bar for deterioration or damage. /
l Check the stabilizer link ball joint dust cover for cracks.
CHECKING OF STABILIZER LINK BALL JOINT FOR START-
ING TORQUE
(2) ~~f~~~t side to side the stabilizer link ball joint stud several
times.
Standard value: 1.7-3.2 Nm (15-28 in.lbs.)
value, replace the stabilizer link.
drag and excessive play.
BALL JOINT DUST COVER REPLACEMENT

(1) Remove the clip ring and the dust cover.
12LO244
(2) Apply multipurpose grease to the lip and inside of the dust
cover.
PART No. 2525035 or equivalent
12LO217
(3) Use vinyl tape to tape the stabilizer link where shown in the
illustration, and then install the dust cover to the stabilizer
link.
(4.) Secure the dust cover by the clip link.
12LQ242
-
FRONT SUSPENSION - Stabilizer Bar 241
SERVICE POINTS OF INSTALLATION NO2lDAK
13. INSTALLATION OF STABILIZER BAR FRACKET

(1) Temporarily tighten the stabilizer bar bracket: ’
(2) Align the bushing end with the marked part of the
stabilizer bar, and then fully tighten the stabilizer. bar
3 *!-Marking bracket.
A I I\/ \ \lZAOOOE
10. INSTALLATION OF STABILIZER LINK MOUNTING NUT

both ends of the stabilizer link, tighten the mounting nuts.
6. INSTALLATION OF STABILIZER BAR MOUNTING NUT

Tighten the nut on the stabilizer bar bolt to the specified
distance.
Standard value:
Protruding length of stabilizer bar
mounting bolt 16-18 mm (.63-.70 in.)
2-42 FRONT SUSPENSION - Stabilizer Bar
STABILIZER BAR <AWD> N02TA-B

Post-installation Operation
l Removal of Front Exhaust Pipe *Installation of Front Exhaust Pipe
(Refer to GROUP 11 -Exhaust Pipe (Refer to GROUP 11 -Exhaust Pipe
and Main Muffler.)
I
<M/T> 8
55-60 Nm
40-43 ftlbs.
<A/T>
60-80 Nm
43-58 ft.lbs.
12A0314
80-100 Nm
58-72 ft.lbs. --A
35-45
Removal steps 25-33
12AO352
Left member
Gusset 4
Transfer
Stabilizer link installation nut
Stabilizer link
Stabilizer bar bracket installation NOTE
I)4 7 . Sgabibi~;r bar bracket (I) Reverse the removal procedures to reinstall.
8. (2) 4* : Refer to “Service Points of Removal”.
l * 9. Stabilizer bar (3) l 4 : Refer to “Service Points of Installation”
SERVICE POINTS OF REMOVAL NOZlBAG
4. REMOVAL OF STABILIZER LINK MOUNTING NUTS

both ends of the stabilizer link, remove tfie mounting nuts,
1 9. REMOVAL OF STABILIZER BAR

(1) Disconnect the coupling of the knuckle and lower arm
at the right side.
(2) Pull out the left side stabilizer bar edge, pulling it out
between the drive shaft and lower arm.
(3) Pull out the right side stabilizer bar edge, pulling it out
from below the lower arm.
NOZTCAH
INSPECTION
Refer to P.2-40.
BALL JOINT DUST COVER REPLACEMENTNomD

Refer to P.2-40.
NOZTDAN
SERVICE POINTS OF INSTALLATION
7. INSTALLATION OF STABILIZER BAR BRACKET!
4. STABILIZER LINK INSTALLATION NUT
Refer to P.2-41.
2-44 FRONT SUSPENSION - Centermember and Crossmember
CENTERMEMBER AND CROSSMEMBER <FWD>

Pre-removal Operation Post-installation Operation

l Disconnection of the Front Exhaust Pipe *Lower the Engine
when removing the Crossmember (Re- l coupling of the Front Exhaust Pipe (Re-
fer to GROUP 1 l-Exhaust Pipe and fer to GROUP ll-Exhaust Pipe a n d
Main Muffler.) Main Muffler.)
@Raise and Suspend the Engine to the @Air bleeding of the Power-steering Fluid
Extent Force is not applied to the Engine (Refer to GROUP 19-Service Adjust-
ment Procedures.)
*Adjustment of the Front Wheel Align-
ment
(Refer to GROUP 2-Service Adjustment
Procedures.)
40-50 Nm
29-36 ft.lbs.
!I”-*J-- 70-86 Nm
51-58 ft.lbs.
9
\
7
80-100 Nm
80-100 Nm 58-72 ft.lbs. llA0283
58-72 ft.lbs.
Removal steps
1. Front roll stopper bracket mounting bolt
2. Centermember installation bolts (front)
3. Stopper
4. Bushing
5. Bushing
6. Collar
7. Centermember installation bolts (rear)
8. Centermember NOTE
9. Stay Reverse the removal procedures to reinstall.
FRONT SUSPENSION - Centermember and Crossmember 2-45
<Rubber-bushing type stabilizer bar>
27 .- Nm
X0-42 .-___
-ii-30 ft.lbs.
<Pillow-ball type stabilizer bar>
35-45
25-33
~~ 10. Self locking nut

11. Joint cup +e l 4 22. Nut Pillow-ball type
12. Stabilizer rubber 23. Stabilizer link > stabilizer bar
13. Stabilizer bar 24. Stabilizer bar bracket
installation bolt installation bolt
14. Joint cup I)4 25. Stabilizer bar bracket
15. Stabilizer rubber Rubber-bushing 26. Bushing
type stabilizer bar 4* 27. Stabilizer bar
16. Joint cup
17. Stabilizer rubber
18. Joint cup NOTE
19. Collar (1) Reverse the removal procedures to reinstall.
(21 4* : Refer to “Service Points of Removal”.
20. Joint cup i3j l * : Refer to “Service Points of Installation”.
21. Stabilizer rubber : (4) m : Non-reusable parts
15-20 Nm
11-14 ft.lbs.
12-18 Nm
9- 13 ft.lbs.
9 - 1 4 Nm
7-10 ft.lbs.
60-60 Nm OlA0473
43-58 ft.lbs.
28. Cotter pin

29. Tie-rod end and connection nut
30. Joint assemblv connection bolt
31. Return tube ’
connection Power steering NOTE A
32. Pressure hose (1) Reverse the removal procedures to reinstall.
connection (2) 4+ : Refer to “Service Points of Removal”. J
33. Mounting bracket (3) l + : Refer to “Service Points of Installation”.
+e l + 34. Steering gear box assembly (4) m : Non-reusable parts
.-
39
40-50 Nm
29-36 ft.lbs.
r---
f
100-120 Nm*
72-87 ft.lbs.*
80-100 Nm
JIY- \I 58-72 ftlbs.
80-lb0 Nm 3\7 !
58-72 ft.lbs. I
80-100 Nm*
58-72 ft.lbs.*
100-120 Nm
72-87 ftlbs.
35. Self locking nut

36. Clamp
37. Lower arm mounting bolt
38. Stopper
39. Rear roll stopper bracket mounting bolt
40. Self locking nut FFEeverse the removal procedures to reinstall.
41. Lower plate (2) m : Non-reusable parts
42. Crossmember (3) * : Indicates parts which should be temporarily tight-
43. Stopper ened, and then fully tightened with the vehicle in
44. Bushing the unladen condition.
SERVICE POINTS OF REMOVAL N02YBAEa
22. REMOVAL OF NUT

Refer to P.2-39.
27. REMOVAL OF STABILIZER BAR
Refer to P.2-39.
34. REMOVAL OF STEERING GEAR BOX ASSEMBLY
Refer to GROUP 19-Steering Gear Box.
INSPECTION N02YCMl
l Check the crossmember for cracks or deformation.

l Check the bushings for cracks or deterioration.
l Check the centermember for cracks or deformation.
Press out Press fit BUSHING REPLACEMENT NOZYDAAa
(1) Remove and press in bushings A and B using the illustrated

method.
(2) Press in bushings A and B so that the projecting amount
of the inner sleeve agrees with the standard value.
Standard value:
Bushing A 7.2-10.2 mm (.28-.40 in.)
Bushing B 6.5-9.5 mm (.26-.37 in.)
Caution
When pressing in, apply a solution of soap and water to
the sliding part of the bushings, and then press them in
Bushing A Bushing B without stopping one after the other.
If there is a pause during the pressing operation, the
frictional resistance will prevent installation.
Inner sleeve
12R0128 12RO129
SERVICE POINTS OF INSTALLATION NOZYEAEa
34. INSTALLATION OF STEERING GEAR BOX ASSEMBLY

25. INSTALLATION OF STABILIZER BAR
Refer to P.2-41.
10./22. INSTALLATION OF SELF LOCKING NUT/NUT
Refer to P.2-41.
CENTERMEMBER AND CROSSMEMBER <AWD>
- REMOVAL AND INSTALLATION NOZYA-B
40-50 Nm
29-36 ft.lbs.
50-65 Nm
36-47 ft.lbs.
-30 ll.l”S., 70-80 Nm
e ~ 51-58 ft.lbs. 7n-~0

I” .s-
Nm
.w...
80-I:0 Nm 51-58 ft.lbs.

58-72 ft.lbs.
3 '
/ I
-Y-- /
70-80 Nm
1 7 t
80-100 Nm 51-58 ft.lbs.
58-72 ft.lbs.
OlA0619
80-100 Nm 70-80 Nm
58-72 ftlbs. 51-58 ftlbs.
Removal steps
1. Cover installation screw
2. Left member
3. Right member
4. Front roll stopper installation bolt
5. No. 1 crossmember installation nut
6. Lower plate Post-installation Operation
7. No. 1 crossmember l Air bleeding of the Power-steering Fluid
8. (Refer to GROUP 19-Service
9. Bushing (B)
10. Gusset *Adjustment
P.2-8.)
NOTE
(I)
40-60 Nm
29-43 ftlbs.
A
“1 I
30-40 Nm
22-29 ftlbs.
A’
40-60 /Nm IO-15 Nm

29-43 ftlbs. 7- 11 ftlbs.
11. Front exhaust pipe rear installation bolts 05AO169

12. Gasket
14. Front exhaust pipe
15. Gasket
22-30 ftlbs.
35-45
25-33 12AO352
+e MI 16. Stabilizer link installation nut

17. Stabilizer link $?everse the removal procedures to reinstall.
18. Stabilizer bar bracket installation bolts (2) +* : Refer to “Service Points of Removal”.
l 19. Stabilizer bar bracket (3) l 4 : Refer to “Service Points of Installatron”.
20. Bushing
4* 21. Stabilizer bar ct
J’
15-20 Nm
11-14 ft.lbs.
\ 25
\ 09*0055
<M/T> 12-18 Nm
55-60 Nm 22 9 - 1 3 ft.lbs.
40-43 ftlbs.
<A/T>
60-80 Nm a
43-58 ftlbs.
OlA0473
60-80 Nm
42-58 ft.lbs.
22. Transfer assembly

23. Cotter pin Fykeverse the removal procedures to reinstall.
24. Tie-rod end connection nut (2) ~~ : Refer to “Service Points of Removal”.
25. Joint assembly connection bolt (3) l + : Refer to “Service Points of lnstallatron”
26. Return tube connection
27. Pressure hose connection
28. Mounting bracket
+e l + 29. Steering gear box assembly
FRONT SUSPENSION - Centermember and Crossmember
34
40-50 Nm
29-36 ftlbs.
38
-39
-36
100-120
72-87 ft ‘350
’ 80-100 Nm
56-72 ft.lbs. 32 ; 58-72 ft.lbs.
60-100 Nm*
58-72 ft.lbs.*

31. Clamp
32. Lower arm mounting bolt
33. Stopper
34. Rear roll stopper bracket mounting bolt OlA0641
36. Lower plate
37. Crossmember
38. Stopper
39. Spacer
40. Bushing
NOTE
(1) Reverse the removal procedures to reinstall.
(3) * Indicates parts which should be temporarily tightened,
and then fully tightened with the vehicle in the unladen
condition.
SERVICE POINTS OF REMOVAL NOZYBAF
16. REMOVAL OF STABILIZER LINK INSTALLATION NUT/

21. STABILIZER BAR
Refer to P.2-39.
29. REMOVAL OF STEERING GEAR BOX ASSEMBLY
INSPECTION NOZYCAA2
l Check the crossmember for cracks or deformation.

l Check the bushings for cracks or deterioration.
l Check the centermember for cracks or deformation.
BUSHING REPLACEMENT NOZYDAB
Refer to P.2-48.
SERVICE POINTS OF INSTALLATION N02YEAF
29. INSTALLATION OF STEERING GEAR BOX ASSEMBLY

19. INSTALLATION OF STABILIZER BAR BRACKET/
16. STABILIZER LINK INSTALLATION NUT
Refer to P.2-41.
NOTES
3-1
REAR AXLE
CONTENTS
AXLE SHAFT ........ . ............................ . ............. 10 Differential (Conventional Differential)

Bearing noise while driving or coasting
DIFFERENTIAL CARRIER ................................ 19
Constant noise
DRIVE SHAFT .................................................. 13 Gear noise while coasting
Gear noise while driving
SERVICE ADJUSTMENT PROCEDURES.. ..... 8
Heat
Gear Oil Level Check ................................... 8
Noise while turning
Limited Slip Differential Check .................... 9
.. Oil leakage
Rear Axle Total Backlash Check ................. 8
Differential (Limited Slip Differential)
Rear Wheel Bearing End Play Check ......... 8
Abnormal noise during driving or
Rear Wheel Bearing Rotation Sliding gear changing
Resistance Check ......................................... 9
Abnormal noise when cornering
SPECIAL TOOLS ............................................. 4 Break down
Gear noise
SPECIFICATIONS ............................................. 2
Gear oil leakage
General Specifications .................................. 2
Seizure
Lubricants ...................................................... 3
The limited slip differential does
Sealants and Adhesives ............................... 3 not function
Service Specifications ................................... 2 Drive Shaft
Torque Specifications ................................... 3 Noise
TROUBLESHOOTING ...................................... 6
Axle Shaft
Grease leakage
Noise while wheels are rotating
3-2 REAR AXLE - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NO3CA- h
Items Vehicles with Vehicles with
conventional differential limited slip differential
Axle shaft
Type Semi-floating type Semi-floating type
Shaft dimensions
Outer bearing portion dia. mm (in.) 35 (1.38) 35 (1.38)
Inner bearing portion dia. mm (in.) 28 (1.10) 28 (1.10)
Center portion dia. mm (in.) 34.5 (1.36) 34.5 (1.36)
Overall length mm (in.) 214.9 (8.46) 214.9 (8.46)
Bearing
O.D. x I.D. Outer mm (in.) 72 x 35 (2.83 x 1.38) 72 x 35 (2.83 x 1.38)
Inner mm (in.) 58 x 28 (2.28 x 1.10) 58 x 28 (2.28 x 1.10)
Drive shaft
Joint type Outer D.O.J. D.O.J.
Inner B.J. B.J.
Length (joint to joint) x diameter mm (in.) 397 x 24 (15.6 x .94) 397 x 24 (15.6 x .94)
Differential
Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 3.545 <MiT>, 3.307 <AI-~> 3.545 <M/T>, 3.307 <AI-f>
Differential gear type and configuration
Side gear Straight bevel gear x 2 Straight bevel gear x 2
A
Pinion gear Straight bevel gear x 2 Straight bevel gear x 4
Number of teeth
Drive gear 3 9 <Ml-f>. 43 <AI-f> 39 <MIT>, 43 <AA>
Drive pinion 11 <M/T>, 13 <Al-f> ll<M/T>, 13 <A/‘-f>
Side gear 14 16
Pinion gear 10 10
NOTE
D.O.J.: Double offset joint
B.J.: Birfield joint
SERVICE SPECIFICATIONS NOBCB-
Items Specifications
Standard value
Rear wheel bearing rotation sliding resistance N (Ibs.) [Nm (in.lbs.)l 12 (2.6) [0.7 (6)l o r l e s s
Setting of D.O.J. boot length m m ( i n . ) 76+3 (3.00+.12)
Final drive gear backlash mm (in.) 0.1 l-0.16 (.004-,006)
Differential gear backlash mm (in.)
Conventional differential O-0.076 (O-.003)
Limited slip differential 0.03-0.09 (.0012-.0035)
Drive pinion rotation starting torque
with oil seal Nm (in.lbs.)
New part 1.0-1.3 (9-11)
New part/reusable part 0.5-0.6 (4-5)
without oil seal Nm (in.lbs.)
New part 0.9-I .2 (8-10)
New part/reusable part 0.4-0.5 (3-4)
REAR AXLE - Specifications
Limit
Rear axle total backlash mm (in.) 5 (.2)
Drive gear runout mm (in.) 0.05 (.002)
Rear wheel bearing end play mm (in.) 0.8 (.031)
Differential gear backlash mm (in.) 0.2 (.008)
TORQUE SPECIFICATIONS
Items Nm ft.lbs.
Drive shaft to companion flange 55-65 40-47

Axle shaft installation nut 160-220 116-159
Rear brake assembly installation bolts 50-60 36-43
Rear speed sensor brackets 9-14 7-10
Differential carrier to crossmember 100-120 72-87
Differential carrier to propeller shaft 30-35 22-25
Differential carrier to differential support member 80- 100 58-72
Differential support member to bolt 110-130 80-94
Drain plug 60-70 43-51
Filler plug 40-60 29-43
Companion flange to drive pinion 160-220 116-159
Bearing cap installation bolt 40-60 29-43
Drive gear
to differential case 80-90 58-65
Cover gear carrier
to 30-42 22-30
LUBRICANTS
Rear axle gear oil MOPAR Hypoid Gear Oil API classification GL-5 or higher 0.7 lit. (0.74 qts.
Above -23°C (-10°F) SAE 90, 85W-90, 8OW-90
F r o m -34°C (-30°F) to -23°C (-10°F) S A E 8OW, 8OW-90
Below -34°C (-30°F) SAE 75W
B.J. boot grease Repair kit grease 90 g (3.2 dz.)
D.O.J. boot grease
Seal lip of outer bearing MOPAR Multi-Mileage Lubricant Part No.2525035 or equivalent As required
Trailing arm oil seal lip
Oil seal lip of side bearing
Washer of special tool
(M B990836)
Oil seal lip of drive pinion
Differential companion
flange washer
SEALANTS AND ADHESIVES

..-
Items Specified sealants and adhesives I
Vent plug 3M ATD Part No.8661, 8663 or equivalent
Differential cover
Drive gear threaded hole MOPAR Part No.4318031 or 4318032 or equivalent

REAR AXLE - SDecial Tools
SPECIAL TOOLS N03DA--
Tool Number Name Use

MB990767 End yoke holder Measurement of rotation torque of the limiter
slip differential
Stop axle shaft turning
/
CT-l 003 Axle shaft puller Press-fitting the drive pinion rear bearing oute
race
Sliding hammer set Removal of the axle shaft
MB990560 Bearing remover Removal of the axle shaft dust cover, oute
bearing and rear rotor
Press-in the outer wheel bearing and rear rotor
MB991115 Oil seal installer Press-fitting of drive shaft oil seal
Side bearing puller Removal of the side

REAR AXLE - Special Tools 3-5
Number Name 1 Use
Bearing remover
easuremen
ng of the side bearing inner race
Installer bar
f the drive pinion bearing outer

3-6 REAR AXLE - Troubleshooting
TROUBLESHOOTING NO3EA-
Symptom Probable cause Remedy

AXLE SHAFT
Noise while wheels are Brake drag Replace
rotating Bent axle shaft
Worn or scarred axle shaft bearing
Grease leakage Worn or damaged oil seal Replace
Malfunction of bearing seal
DRIVE SHAFT
Noise Wear, play or seizure of ball joint Replace
Excessive drive shaft spline looseness
DIFFERENTIAL (CONVEN-
TIONAL DIFFERENTIAL)
Constant noise Improper final drive gear tooth contact adjustment Correct or replace
Loose, worn or damaged side bearing
Loose, worn or damaged drive pinion bearing
Worn drive gear, drive pinion Replace
Worn side gear spacer or pinion shaft
Deformed drive gear or differential case
Damaged gear
Foreign material Eliminate the foreign material
and check; replace the parts if
necessary
Insufficient oil Replenish
Gear noise while driving Poor gear engagement Correct or replace
Improper gear adjustment
Improper drive pinion preload adjustment
Damaged gear Replace
Foreign material Eliminate the foreign material
and check; replace the parts if
necessary
Gear noise while coasting Improper drive pinion preload adjustment Correct or replace
Damaged gear Replace
Bearing noise while driving Cracked or damaged drive pinion rear bearing Replace
or coasting .-
Noise while turning Loose side bearing Replace
Damaged side gear, pinion gear or pinion shaft
Heat Insufficient gear backlash Adjust
Excessive preload
Oil leakage Clogged vent plug Clean or replace
Cover insufficiently tightened Retighten, apply sealant, or re-
Seal malfunction place the gasket
Worn or damaged oil seal Replace
Excessive oil Adjust the oil level
DIFFERENTIAL (LIMITED
SLIP DIFFERENTIAL)
Abnormal noise during driv- Excessive final drive gear backlash Adjust
ing or gear changing Insufficient drive pinion preload
Excessive differential gear backlash Adjust or replace
Worn spline of a side gear Replace
Loose companion flange self-locking nut Retighten or replace
REAR AXLE - Troubleshooting 3-7
Symptom 1 Probable cause 1 Remedy
NOTE
In addition to a malfunction of the differential carrier components, abnormal noise can also be caused by the universal
joint of the propeller shaft, the axle shafts, the wheel bearings, etc. Before disassembling any parts, take all
possibilities into consideration and confirm the source of the noise.
Abnormal noise when Damaged differential gears Replace
cornering Damaged pinion shaft
Insufficient gear oil quantity Replenish
Gear noise Improper final drive gear tooth contact adjustment Adjust or replace
Incorrect final drive gear backlash Adjust
Improper drive pinion preload adjustment
Damaged, broken, and/or seized tooth surfaces of Replace
the drive gear and drive pinion
Damaged, broken, and/or seized drive pinion bear-
ings
Damaged, broken, and/or seized side bearings
Damaged differential case
Inferior gear oil
NOTE
Noise from the engine, muffler vibration, transaxle, propeller shaft, wheel bearings, tires, body, etc., is easily mistaken
as being caused by malfunctions in the differential carrier components. Be extremely careful and attentive when
performing the driving test, etc.
Test methods to confirm the source of the abnormal noise include: coasting acceleration, constant speed driving,
raising the rear wheels on a jack, etc. Use the method most appropriate to the circumstances.
Gear oil leakage Worn or damaged front oil seal, or an improperly Replace
installed oil seal
Damaged gasket
Loose companion flange self-locking nut Retighten or replace
Loose filler or drain plug Retighten or apply adhesive
Clogged or damaged vent plug Clean or replace
Seizure Insufficient final drive gear backlash Adjust
Excessive drive pinion preload
Excessive side bearing preload
Insufficient differential gear backlash
Excessive clutch plate preload
Inferior gear oil Replace
VOTE
n the event of seizure, disassemble and replace the parts involved, and also be sure to check all components for any
rregularities and repair or replace as necessary.
3reak down Incorrect final drive gear backlash Adjust
Insufficient drive pinion preload
Insufficient side bearing preload
Excessive differential gear backlash
Loose drive gear clamping bolts Retighten
VOTE
n addition to disassembling and replacing the failed parts, be sure to check all components for irregularities and repair
Ir replace as necessary.
The limited slip differential The limited slip device is damaged Disassemble, check the func-
lees not function (on tioning, and replace the dam-
;now, mud, ice, etc.) aged parts
3-8 REAR AXLE - Service Adjustment Procedures

REAR AXLE TOTAL BACKLASH CHECK N03FAAF
If the vehicle vibrates and produces a booming sound due to an

imbalance of the driving system, measure the rear axle total
backlash by the following procedures to see if the differential
carrier assembly required removal.
(1) Place the gearshift lever in the neutral position, apply the
parking brake and jack up the vehicle.
(2) Manually turn the propeller shaft clockwise as far as it will

go and make mating marks on the companion flange dust
cover and the differential carrier.
(3) Manually turn the propeller shaft counterclockwise as far as

it will go and measure the movement of the mating marks.
Limit: 5 mm (.2 in.)
(4) If the backlash exceeds the limit, remove the differential
carrier assembly and adjust the backlash. (Refer to P.3-20.)
GEAR OIL LEVEL CHECK N03FCAA
1. Remove the filler plug, and check the oil level.

2. The oil level is sufficient if it reaches the filler plug hole.
Specified gear oil:
MOPAR Hypoid Gear Oil API classification GL-5 or
higher [0.7 liter (0.74 qts.)]
NOTE
Above -23°C (-10°F): SAE 90, 85W-90, 8OW-90
F r o m -34°C (-30°F) to -23°C (-10°F): SAE 8OW,
8OW-90
Below -34°C (-30°F): SAE 75W
09D031 REAR WHEEL BEARING END PLAY CHECKN03FEAE

(1) Support the vehicle on axle stands positioned at the
specified locations and remove the rear wheel.
(2) Separate the parking brake cable from the rear brake.
(3) Remove the caliper assembly and brake disc.
(4) Place a dial gauge as shown in the figure, and then
measure the play when the axle shaft is moved in the axial
direction.
Limit: 0.8 mm (.031 in.)
(5) If the play exceeds the limit, check the tightening torque of
the companion flange of the axle shaft; if it is correct,
llA0065 replace the wheel bearing.
REAR AXLE - Service Adjustment Procedures 3-9
REAR WHEEL BEARING ROTATION SLIDING
RESISTANCE CHECK NOOFJAA
(1) Remove the drive shaft from the companion flange.

(2) Remove the brake pad or caliper assembly.
(3) Attach a spring balance to the hub bolt, then, pulling the
balance at a right angle to the hub bolt, measure the
rotation sliding resistance (rotation starting torque) to see
whether it is within the standard value.
Standard value: 12 N (2.6 Ibs.) [rotation starting tor-
14A0521
que 0.7 Nm (6 in Ibs.)] or less
(4) If the rotation starting torque exceeds the standard value,
check the tightening torque of the axle shaft companion
Incorrect flange. If it is normal, replace the bearing.
LIMITED-SLIP DIFFERENTIAL CHECK NOJFIAA
(1) Block the front wheels and move the shift lever to neutral.
(2) Completely release the parking brake.
(3) Jack up the rear wheels and place a rigid rack at the
specified part of the side sill.
(4) Disconnect the coupling of the differential and propeller
shaft.
(5) When one wheel is slowly rotated, check whether or not
the wheel on the other side turns in the same direction.
(6) If it turns in the opposite direction, replace the viscous unit.
_--
3-10 REAR AXLE - Axle Shaft
AXLE SHAFT
AL
REMOVAL AND INSTALLATION NOBHA-

*Disconnecting of Parking Brake Cable Konnecting of Parking Brake Cable End
End aAdjusting Parking Brake Lever
Stroke (Refer to GROUP 5-Service
55-65 Nm
40-47 ft.lbs. 160-220 Nm
! 116- 159 I ft.lbs. 50-60 36-43 ft.lbs. Nm
9-14 Nm
7-W ft.lbs.
llA0360
/
Removal steps 4
4* 1. Rear speed sensor <Vehicles with A B S>
2. O-ring
c* 3. Brake caliper assembly
4. Brake disc
5. Drive shaft mounting nut
+e l + 6. Self-locking nut
7. Washer
8. Companion flange
c+ 9. Axle shaft assembly
4I) +4 10. Rear rotor <Vehicles with A B S>
+e ++ 11. Outer bearing
*e ++ 12. Dust cover NOTE
++ 13. Dust cover (1) Reverse the removal procedures to reinstall.
14. Axle shaft (2) *I) : Refer to “Service Points of Removal”.
4* +4 15. Oil seal (3) l + : Refer to “Service Points of Installation”.
+e l + 16. Inner bearing (4) m : Non-reusable parts
SERVICE POINTS OF REMOVAL NOBHBAP
1. REMOVAL OF REAR SPEED SENSOR <VEHICLES WITH

ABS>
NOTE
Be cautious to ensure that the tip of the pole piece does not A
come in contact with other parts when removing the speed c
sensor.
3. REMOVAL OF BRAKE CALIPER ASSEMBLY
Remove the brake caliper assembly and suspend it with a
piece of wire.
REAR AXLE - Axle Shaft 3-11
With the special tool, secure the axle shaft and remove the
companion flange self-locking nut.
9. REMOVAL OF AXLE SHAFT ASSEMBLY

With the special tool, remove the axle shaft from the
trailing arm.
12A0611
10. REMOVAL OF REAR ROTOR <VEHICLES WITH A B S>

Remove the rear rotor from the axle shaft.
1 11. REMOVAL OF OUTER BEARING/lZ. DUST COVER

With the special tool, remove the outer bearing and dust
cover concurrently from the axle shaft.
MB990560
Trailing arm 1 15. REMOVAL OF OIL SEAL/lG. INNER BEARING

/
With the special tool, remove the inner bearing and oil seal
from the trailing arm.
INSPECTION NOBHCAF
l Check the companion flange for wear or damage.

l Check the dust cover for deformation or damage.
l Check the wheel bearings for burning or discoloration.
l Check the wheel bearing for unsmooth rotation.
/
MB990928 l Check the axle shaft for cracking, wear or damage.
11 A0038 l Check oil seal for cracking or damage.
3-12 REAR AXLE - Drive Shaft
7
SERVICE POINTS OF INSTALLATION N03HDAR
Trailing arm 16. INSTALLATION OF INNER BEARING

c-4171
/ With the special tool, press fit the inner bearing onto the
F
trailing arm.
MB960931
1 lA0039
15. INSTALLATION OF OIL SEAL
(1) With the special tool, press fit the oil seal onto the
trailing arm with the depression in the oil seal facing
Trailing arm M B990799 upward, and until it contacts the shoulder on the inside
of the inner arm.
NOTE
When tapping the oil seal in, use a plastic hammer to
lightly tap the top and circumference of the special tool,
press fitting gradually and evenly.
(2) Apply multipurpose grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant
11 A0040 Part No.2525035 or equivalent
13. INSTALLATION OF DUST COVER

Orienting the dust cover as shown in the illustration, and
using the special tool, press fit the dust cover until it
contacts the axle shaft shoulder.
NOTE
When tapping the oil seal in, use a plastic hammer to lightly
tap the top and circumference of the special tool, press
fitting gradually and evenly.
12. INSTALLATl,ON OF DUST COVER

With the special tool, install the dust cover so that the
depression is facing upward.
NOTE
When tapping the oil seal in, use a plastic hammer to lightly
tap the top and circumference of the special tool, press
fitting gradually and evenly.
11. INSTALLATION OF OUTER BEARING

(1) Apply multi-purpose grease around the entire cir-
cumference of the inner side of the outer bearing seal
lip.
(2) With the special tool, press fit the outer bearing to the
axle shaft so that the bearing seal lip surface is facing
towards the axle shaft flange.
llAO263
REAR AXLE - Axle Shaft/Drive Shaft 3-13
10. INSTALLATION OF REAR ROTOR <VEHICLES WITH
ABS>
Press fit the rear rotor to the axle shaft with the rear rotor
groove surface toward the axle shaft flange.
6. INSTALLATION OF SELF LOCKING NUT

With the special tool, secure the axle shaft and tighten the
companion flange self locking nut.
DRIVE SHAFT N03JA--
PARTS DISTINCTION
-- Boots and boot bands can be distinguished by the
F
1 D.O.J. boot 1 n B.J. boot band
I
Iidentification number
Ilocation
3-‘14 REAR AXLE - Drive Shaft
55-65 N.m
40-47 ft.lbs.
Removal steps
1. Bolt
+e l 4 2. Drive shaft
3. Circlip
l * 4. Oil seal
NOTE
<-, l * : Refer to “Service Points of Removal”.
(2)
(3) ii: Refer to “Service Points of Installation”.
(4) q : Non-reusable parts llA0324
SERVICE POINTS OF REMOVAL NO3JEAD
2. REMOVAL OF DRIVE SHAFT

Using a tire lever, etc. remove the drive shaft from the
,-
differential carrier.
INSPECTION NOJJHAA
l Check the drive shaft boots for damage or deterioration.

l Check the ball joints (B.J. and D.O.J.) for excessive play or
check operation.
l Check the drive shaft spline for wear or damage.
SERVICE POINTS OF INSTALLATION N03JCAE

(1) If the oil seal is to be replaced because of damage, drive
it in by using the special tool.
(2) Apply the specified grease to the oil seal lip. -

Part No.2525035 or equivalant
llK110 llK610
REAR AXLE - Drive Shaft
2. INSTALLATION OF DRIVE SHAFT I_ ,T

Caution
Boot band C 1. Be cautious to ensure that the differential carrier oil
seal is not damaged by the drive shaft spline.
2. The drive shafts for models equipped with the
limited-slip differential are of different length and,
in addition, the right drive shaft has a two-part
serration; be very careful to install each one on the
Two-part serration correct side.
llA0280
NOTE
The left and right drive shafts can also be distinguished
from each other by the identification color of boot band
C.
I Item
I
Drive shaft
(left)
Boot band C identification color Yellow
I
Drive shaft
(right)
Blue
I
3. Be sure to thoroughly remove any oil or grease, etc.

from the threaded part of the bolt and nut used for
installation to the companion flange, because any
oil, grease, etc. on these parts might cause later
loosening even though tightening is at the specified
torque.
N03JD--
Drive shaft and B.J. kit
1 lA6969 1 lAO967
D.O.J. kit B.J. boot repair kit
Disassembly steps Reassembly steps

I. Circlip 16. Drive shaft and B.J.
2. Boot band(B) 15. Dust cover
3. Boot band (C) l + 14. B.J. boot
4. Circrip l + 12. Boot band (A)
5. D.O.J. outer race l + 13. Boot band (C)
6. Snap ring l + 3. Boot band (Cl
7. D.O.J. Inner race, cage and ball assembly l + 2. Boot band(B)
8. Balls l + 11. D.O.J. boot
9. D.O.J. inner race l + 7. D.O.J. inner race, cage and ball assembly
10. D.O.J. cage 10. D.O.J. cage
11, D.O.J. boot 9. D.O.J. inner race
12. Boot band (A) 8. Balls
13. Boot band (C) 6. Snap ring
14. B.J. boot I)+ 5. D.O.J. outer race
15. Dust cover 4. Circlip
16. Drive shaft and B.J. I. Circlip
!ygeverse the disassembly procedures to reassemble.

(2) +* : Refer to “Service Points of Disassembly”.
(3) I)+ : Refer to “Service Points of Reassembly”.
REAR AXLE - Drive Shaft 3-17
SERVICE POINTS OF DISASSEMBLY NO3JEAC
6. REMOVAL OF SNAP RING/8. BALLS/S. D.O.J. INNER

RACE/IO. D.O.J. CAGE
(1) Remove the snap ring with the snap ring pliers and then
remove the D.O.J. inner race, the D.O.J. cage, and the
balls as a unit.
(2) Clean the D.O.J. inner race, the D.O.J. cage, and the
balls, without dismantling them.
Caution
11 ES07 1. Be careful that balls do not drop out of the cage.
2. If the balls drop out, press them back into the
D.O.J. cage with the D.O.J. inner race.
I I. REMOVAL OF D.O.J. BOOT/I4. B.J. BOOT
(1) Wipe the grease off of the spline portion.
(2) Remove the D.O.J. boot and B.J. boot.
NOTE
If the boots are reused, wrap vinyl tape around the drive
shaft spline so that the boots are not damaged when
they are removed.
Caution
llYO97 Do not disassemble the B.J.
INSPECTION NOJJFAC
l Check the drive shaft for damage, bending or corrosion.

l Check the drive shaft spline for wear or damage.
.- l Check the B.J. for entry of water and/or foreign material.
l Check the D.O.J. outer race for damage or corrosion.
l Check the D.O.J. cage, balls and D.O.J. inner race for
damage, corrosion or wear.
SERVICE POINTS OF REASSEMBLY N03JGAD
14. INSTALLATION OF B.J. BOOT/I*. BOOT BAND (A)/I3.

BOOT BAND (C)/3. BOOT BAND (C)/2. BOOT BAND
(B)/II. D.O.J. BOOT
(1) Wrap vinyl tape around the drive shaft spline.
(2) Insert the drive shaft in B.J. boot, boot band (A), (C), (C),
(B), D.O.J. boot in that sequence.
Boot bands D.O.J. boot

8.J: boot llW592
(3) Fill the inside of the B.J. and B.J. boot with the
specified grease.
Specified grease: Repair kit grease 90 g (3.2 oz.)
Caution
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the
boot.
A special type of grease is used on the joint. Be
cautious to ensure that not other grease is allowed
11KOOO
to come in contact with the joint.
(4) Secure the B.J. boot with boot bands (A) and (C) to the
drive shaft and B.J.
-
ring Caution
\ Ensure that the B.J. is at a zero angle with the drive
shaft to ensure the boot contains the specified
amount of air.
Inner race
1180116
7. INSTALLATION OF D.O.J. INNER RACE, CAGE AND

BALL ASSEMBLY
(1) Apply the specified grease to the D.O.J. cage, the balls
and the D.O.J. inner race.
Specified grease: Repair kit grease (As required)
(2) Install the cage, balls and inner race to the drive shaft,
then, using the snap ring pliers, fit the snap ring
securely into the groove in the shaft.
llE507
5. APPLICATION OF GREASE TO D.O.J. OUTER RACE

(1) Fill the specified grease to the D.O.J. outer race, fit the
drive shaft into the D.O.J. outer race, and then fill more
grease to the D.O.J. outer race.
Specified grease: Repair kit grease 90 g (3.2 oz.)
Caution
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the
boot.
A special type of grease is used on the joint. Be
cautious to ensure that no other grease is allowed
to come in contact with the joint.
(2) Install the circlip to the D.O.J. outer race.
(3) Assemble the D.O.J. boot to the D.O.J. outer race, then
secure the boot to the drive shaft with boot band (C).
(4) Place boot band (B) on the D.O.J. boot.
NOTE
Do not secure boot band (9)
(5) Set the D.O.J. boot bands at the specified distance in

order to adjust the amount of air inside the D.O.J. boot,
and then tighten the D.O.J. boot band (C) securely.
Standard value: 76+-3 mm (3.00 & .23 in.)
(6) Release a part of the D.O.J. boot from the D.O.J. outer --
race to allow pressure to escape from the boot.
(7) Tighten boot band (9) and secure the D.O.J. boot.
Boot band (8’)

REAR AXLE - Differential Carrier 3-19
DIFFERENTIAL CARRIER
lEMOVAL AND INSTALLATION N03lA--
Pre-removal Operation
@Drainage of Differential Gear Oil (Refer to
P.3-8.)
*Removal of Center Exhaust Pipe (Refer
to GROUP 1 l-Exhaust Pipe and Main
Muffler.)
loo-120 Nm
72-87 ft.lbs.
9-14 Nm
\ 7-10 ft.lbs.
80-100 Nm
58-72 ft.lbs.
loo-120 Nm
72-87 ftlbs. \ /*
55-65 N m
hl
91 A- - /40-47 ftilis.
22-25 ft.lbs.
Removal steps
llA0358
4* I. Drive shaft
2. Circlip
~~ ++ 3. Propeller shaft connection
4. Differential support member installation
nut
5. Stopper (lower)
6. Differential support member installation
I I
bolts NOTE
7. Differential support member (I) Reverse the removal procedures to reinstall
8. Differential support member installation (2) +I) : Refer to “Service Points of Removal”.
bolts (2) W : Refer to “Service Points of Installation”.
9. Differential carrier (3) m : Non-reusable parts.
3-20 REAR AXLE - Differential Carrier
SERVICE POINTS OF REMOVAL N031BAL
1. REMOVAL OF DRIVE SHAFT

With a tyre lever, etc., remove the drive shaft from the
differential carrier.
NOTE
Be cautious to ensure that the differential carrier oil seal is
not damaged by the drive shaft spline.
Mating marks ’ 3. DISCONNECTION OF PROPELLER SHAFT

(1) Place mating marks on the differential companion
flange and flange yoke for reference during reassembly.
(2) Remove the differential carrier and propeller shaft
connection.
(3) Support the propeller shaft with wire.
lODSO5
DIFFERENTIAL SUPPORT MEMBER BUSHING RE-

Beveled place PLACEMENT NOBIYAA
Use the special tool to pull out and press in the differential
support member bushing.
NOTE
Press in the bushing from the beveled part of the differential
support member; press in until the end surface of the bushing
outer cylinder is flush with the support member.
1 lA0274
SERVICE POINTS OF INSTALLATION N03lDAK
3. CONNECTION OF PROPELLER SHAFT

Align the mating marks on the flange yoke and the
companion flange to install the propeller shaft.
INSPECTION BEFORE DISASSEMBLY NOJIEAI
Hold the working base in a vice, and attach the differential

carrier to the working base.
FINAL DRIVE GEAR BACKLASH

With the drive pinion locked in place, measure the final drive
gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference of the
drive gear.
Standard value: 0.11-0.16 mm (.004-.006 in.)
DRIVE GEAR RUNOUT
Measure the drive gear runout at the shoulder on the reverse
side of the drive gear.
Limit: 0.05 mm (.002 in.)
DIFFERENTIAL GEAR BACKLASH

While locking the side gear with the wedge, measure the
differential gear backlash with a dial indicator on the pinion
gear.
Standard value: O-0.076 mm (O-.003 in.)
’ Limit: 0.2 mm (.008 in.)
-
11GOO73
FINAL DRIVE GEAR TOOTH CONTACT

Check the final drive gear tooth contact by following the steps
below.
.- (1) Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.
(2) Insert a brass rod between the differential carrier and the
differential case, and then rotate the companion flange by
hand (once in the normal direction, and then on& in the
reverse direction) while applying a load to the drive gear, so
that the revolution torque [approximately 2.5-3.0 N m
(28-33 in.lbs.)] is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
(3) Check the tooth contact condition of the drive gear and
drive pinion.
llG0076
Standard tooth contact pattern

1 Narrow tooth side
2 Drive-side tooth surface (the side applying power
during forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the side applying pow-
er during reverse movement)
Problem Solution
Tooth contact pattern resulting from exces-

sive pinion height
3 3
The drive pinion is positioned too far from the Increase the thickness of the pinion height adjusting
:enter of the drive gear. shim, and position the drive pinion closer to the
center of the drive gear.
Also, for backlash adjustment, position the drive
gear farther from the drive pinion.
rooth contact pattern resulting from insuffi-

:ient pinion height
3 3
The drive pinion is positioned too close to the center Decrease the thickness of the pinion height adjust-
If the drive gear. ing shim, and position the drive pinion farther from
ihe center of the drive gear.
Also, for backlash adjustment, position the drive
gear closer to the drive pinion.
115642
NOTE
(1) Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear
backlash. The adjustment of drive pinion hight and final drive gear backlash should be repeated until tooth contact
patterns bear a similarity to the standard tooth contact pattern.
(2) When adjustment is not able to obtain a correct pattern, it may be judged that the drive gear and drive pinion have
exceed their usage limits and both gears should be replaced as a set.
DISASSEMBLY
Inspection Before Disassembly

@Final Drive Gear Backlash (Refer to P.3-
20.)
*Differential Gear Backlash
<Conventional type>
(Refer to P.3-21.)
@Drive Gear Runout (Refer to P.3-21.)
aFInal Drove Gear Tooth Contact (Refer to
1/ ;3-21.)’
<Conventional differential>
Oi6 27 i0
\ \\
q l7 18 20 llA0260
<Limited slip differential>
Disassembly steps
1. Differential cover
2. Vent plug 20. Companion llvlI ,flange
,,,ige llA0290
3. Bearing caps -:-- ‘--nt shim
21. Drive pinion front shim
*I) 4. Differential case assembly
5. Side bearing spacers (for preload adjustment) Jstment)
6. Side bearing outer race 22. Drive pinion spacer 3cer
7. Side bearing inner race l * 23. Drive pinion rearrr bearing inner race
8. Drive gear 24. Drive pinion rearrr shim
:z ,Ivl PJ”pinion
(for llUl I I IcIyIit
height adjustment)
adjustment)
l * 9. Lock pin ?C l3.r;. I,-. pinion
25. Drive ..:..;A-
10. Pinion shaft
11. Pinion gears 26. Oil
“II seal
>twI
12. Pinion washers :: 27. Drive

Drive pinionpinion frontfront bearing
bearing
13. Side gears 4* 28. Drive
n-‘..- -‘-‘--
pinion --lrrear bearing
bearing outer
outer race
29. Oil seal
14. Side gear spacers 30. Gear carrier
15. Differential case
16. Limited slip differential case assembly
*I) 17. Self-locking nut NOTE
18. Washer (1) +I) : Refer to “Service Points of Disassembly”.
4* 19. Drive pinion assembly (2) m : Non-reusable parts.
SERVICE POINTS OF DISASSEMBLY N03lGSC
4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY k

Prize out the differential case assembly using hammer ‘-
shafts.
NOTE
When removing the differential case assembly, the re’mov-
al should be accomplished slowly and carefully and caution
paid to ensure that the side bearing outer race is not
dropped.
Keep the right and left side bearings separate, so that they
do not become mixed at the time of reassembly.
7. REMOVAL OF SIDE BEARING INNER RACES
Pull out the side bearing inner races by using the special
tools.
8. REMOVAL OF DRIVE GEAR

(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching bolts in diagonal fi
sequence to remove the drive gear.
9. REMOVAL OF LOCK PIN

Drive out the lock pin with a punch and remove the pinion
gears, pinion washers, side gears and side gear spacers.

Use the special tools to hold the companion flange and
remove the companion flange self-locking nut.
19. REMOVAL OF DRIVE PINION
) Make the mating marks to the drive pinion and
Mating marks companion flange.
NOTE
Mating marks should not be made to the contact
surfaces of companion flange and propeller shaft.
!) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims.
23. REMOVAL OF DRIVE PINION REAR BEARING INNER

RACE
Pull out the drive pinion rear bearing inner race by using the
special tools.
llD237
26. REMOVAL OF OIL SEAL/27. DRIVE PINION FRONT

BEARING
Drive out the drive pinion front bearing from the gear
carrier.
llY175
28. REMOVAL OF DRIVE PINION REAR BEARING OUTER

RACE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
llY176
INSPECTION N03lHAD
l Check thecompanion flange for wear or damage.

l Check theoil seal for wear or deterioration.
l Check thebearings for wear or discoloration.
l Check thegear carrier for cracks.
l Check the drive pinion and drive gear for wear or cracks.
l Check the side gears, pinion gears and pinion shaft for wear
or damage.
l Check the side gear spline for wear or damage.
REASSEMBLY N0311-
<Conventional differential>
40-60 Nm*
B-43 ft.lbs.*
80-90 Nm*
58-65 ft.lbs.*
llA0260
<Limited slip differential>
<Conventional
differential>
11 BOO86
Differential gear set Final drive gear set

llA0290
Reassembly steps 17. Limited slip (viscous coupling) differential

1. Gear carrier case
l * 2. Oil seal l * Adjustment of differential gear backlash
e+ 3. Drive pinion rear bearing outer race 18. Side gear spacers
l + 4. Drive pinion front bearing outer race 19. Side gears
l * Adjustment of pinion height 20. Pinion washers
5. Drive pinion 21. Pinion gears
6. Drive pinion rear shim 22. Pinion shaft
(for pinion height adjustment) l * 23. Lock pin
7. Drive pinion rear bearing inner race l + 24. Drive gear
8. Drive pinion spacer +4 25. Side bearing inner race
l 4 Adjustment of drive pinion preload 26. Side bearing outer race
9. Drive pinion front shim l 4 Adjustment of final drive gear backlash
(for preload adjustment) 27. Side bearing spacers
10. Drive pinion assembly 28. Differential case assembly
11. Drive pinion front bearing inner race 29. Bearing caps
12. Oil seal l 30. Vent plug
13. Companion flange l 31. Differential cover
14. Washer NOTE
15. Self-locking nut (I) I)+ : Refer to “Service Points of Reassembly”.
16. Differential case [Z!/ m : Non-reusable parts.
* : Tightening torque with oil applied.
SERVICE POINTS OF REASSEMBLY NOJUBD
2. PRESS FITTING OF OIL SEAL

(1) With the special tool, press fit the oil seal until it is flush
with the end of the gear carrier.
(2) Apply multipurpose grease to the oil seal lip.
llK010
3. lNSTALLATlON OF DRIVE PINION REAR BEARING

OUTER RACE/4. DRIVE PINION FRONT BEARING
OUTER RACE
71 Press-fit the drive pinion rear and front bearing outer races
into the gear carrier by using the special tools.
Caution
Be careful not to press in the outer race at an angle.
llY181
llY182
l ADJUSTMENT OF PINION HEIGHT

Adjust the drive pinion height by the following procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequence
shown in the illustration.
NOTE
.MB990836 Apply a thin coat of multipurpose grease to the mating
(MB990835) face of the washer of the special tool.
llrm3 Part No.2525035 or equivalent
(2) Tighten the handle of the special tool until the standard
value of drive pinion turning torque is obtained.
(3) Measure the drive pinion turning torque (without the oil
seal).
Standard value:
Rotation torque
(starting friction torque)
Nm (in.lbs.)
V223
I New
None
(with rust-
prevention oil)
I 0.9-1.2 (8-10)
New/reused Oil application 0.4-0.5 (3-4)

NOTE
(I) Gradually tighten the nut of the special tool while
checking the drive pinion turning torque.
(2) Because the special tool cannot be turned one turn, turn
it several times within the range that it can be turned;
then, after fitting to the bearing, measure the rotation
torque.
(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion rear shim of a
thickness which corresponds to the gap between the 21
special tools.
NOTE
Clean the side bearing seat thoroughly. When position-
ing the special tool, be sure that the cut-out sections of
the special tool are in the position shown in the
illustration, and also confirm that the special tool is in
close contact with the side bearing seat.
When selecting the drive pinion rear shims, keep the
number of shims to a minimum.
(5) Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using the special tool.
. ADJUSTMENT OF DRIVE PINION PRELOAD

Adjust the drive pinion turning torque by using the following
procedures:
(1) Fit the drive pinion front shim(s) between the drive .;c
pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion flange to the specified torque by
using the special tools.
NOTE
Do not install the oil seal.
(3) Measure the drive pinion turning torque (without the oil
seal) by using the special tools.
Standard value:
1 New
Y223 New/reused Oil application 0.4-0.5 (3-4)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque by
MB990031 replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum by selecting the drive pinion spacers.
(5) Remove the companion flange and drive pinion once
again.
Drive the oil seal into the gear carrier front lip by using
the special tool.
Apply multipurpose grease to the oil seal lip.
(6) Apply a thin coat of multipurpose grease to the
companion flange contacting surface of the washer
before installing drive pinion assembly.
(7) Install the drive pinion assembly and companion flange
with mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified
torque by using the special tools.
(8) Measure the drive pinion turning torque (with oil seal) to
verify that the drive pinion turning torque complies with
the standard value.
Standard value:
Rotation torque
(starting friction torque)
Nm (in.lbs.)
I I I
I
Y223
If there is a deviation from the standard value, check

whether or not there is incorrect tightening torque of
the companion flange tightening self-lock nut, or incor-
rect fitting of the oil seal.
. ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH

Adjust the differential gear backlash by the following
procedures:
(1) Assemble the side gears, side gear spacers, pinion
gears, and pinion washers into the differential case.
(2) Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
L-
REAR AXLE - Differential Carrier
(3) Adjust the differential gear backlash by the following
procedures:
@ While locking the side gear with the wedge,
measure the differential gear backlash with a dial
indicator on the pinion gear.
NOTE
The measurement should be made for both pinion
gears individually.
II \I I! llGOO73
Limit: 0.2 mm (.008 in.)
@ If the differential gear backlash exceeds the limit,
adjust the backlash by installing thicker side gear
spacers.
@ Measure the differential gear backlash once again,
and confirm that it is within the limit.
NOTE
(1) After adjustment, check that the backlash is the
less than the limit and differential gear rotates
smoothly.
(2) When adjustment is impossible, replace the side
gear and the pinion gear as a set.
23. INSTALLATION OF LOCK PIN

(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points. w
24. INSTALLATION OF DRIVE GEAR

(1) Clean the drive gear attaching bolts.
(2) Use an Ml0 X 1.25 tap to remove the adhesive
adhering to the threaded holes of the drive gear, and
then clean the threaded holes by applying compressed
air.
(3) Apply multipurpose adhesive to the threaded holes of

the drive gear.
Specified adhesive: M O P A R Part No.4318031 or
4318032 or equivalent
(4) Install the drive gear onto the differential case with the A
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
11 S564
25. PRESS-FITTING OF SIDE BEARING INNER RACE
Press-fit the side bearing inner races to the differential case
by using the special tool.
. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH

Adjust the final drive gear backlash by the following
procedures:
(1) Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and
then mount the differential case assembly into the gear
carrier.
NOTE
Select side bearing spacers with the same thickness for
both the drive pinion side and the drive gear side.
(2) Push the differential case to one side, and measure the
clearance between the gear carrier and the side
bearing.
(3) Measure the thickness of the side bearing spacers on

one side, select two pairs of spacers which correspond
to that thickness plus one half of the clearance plus
0.05 mm (.002 in.), and then install one pair each to the
drive pinion side and the drive gear side.
= Thickness of the
spacer on one side
llV241 I
(4) Install the side bearing spacers and differential case

assembly, as shown in the illustration, to the gear
carrier.
(5) Tap the side bearing spacers with a brass bar to fit them
to the side bearing outer race.
4
(6) Align the mating marks on the gear carrier and the
bearing cap, and then tighten the bearing cap.
(7) With the drive pinion locked in place, measure the final
drive gear backlash with a dial indicator on the drive
gear.
NOTE -cc
Measure at four points or more on the circumference of
the drive gear.
llY167
(8) Change the side bearing spacers as illustrated, and then

If backlash is too small
adjust the final drive gear backlash between the drive
gear and the drive pinion.
NOTE
When increasing the number of side bearing spacers,
use the same number for each, and as few as possible.
(9) Check the drive gear and drive pinion for tooth contact.
If poor contact is evident, make adjustment. (Refer to
P.3-22.)
If backlash is too large
(lO)Measure the drive gear runout at the shoulder on the

reverse side of the drive gear.
Limit: 0.05 mm (.002 in.)
(ll)lf the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential ,+
case, and remeasure.
llY168
30. INSTALLATION OF VENT PLUG/31. DIFFERENTIAL
COVER
Apply specified sealant to the installation surface of
vent plug and differential cover.
Specified sealant: 3M ATD Part No.8661, 8663 or
equivalent
11 K604 11K625
3-34 REAR AXLE - Differential Carrier (Limited Slip Differential)
DIFFERENTIAL CARRIER (LIMITED SLIP DIFFERENTIAL)

DISASSEMBLY AND REASSEMBLY NO31K--
Disassembly steps
1. Screw llP0127
l + 2. Differential case A
+e I)+ 3. Thrust washer (L.H.)
4. Viscous unit
I)+ 5. Pinion mate washer
M 6. Differential pinion mate
7. Differential pinion shaft
8. Differential side gear (R.H.)
4+ 9. Thrust washer (R.H.)
l + 10. Differential case 6
INSPECTION BEFORE DISASSEMBLY NO3IEBA
Feeler gauge
1. CHECKING THE DIFFERENTIAL GEAR BACKLASH
(1) Secure the differential case assembly in a vise so that
the differential side gear (right) is facing upward.
Caution
When securing the vise, be sure not to hold the
differential case assembly too tightly.
(2) Insert a 0.03 mm (.0012 in.) feeler gauge at two places
(diagonally) between differential case B and the thrust
washer (right).
Caution
Feeler gauge Do not insert a feeler gauge in the oil groove of
-eeler gauge differential case B.
\ /
’ I L4l\ II
’
Differential side Thrkt washer
aear (riaht) (right) \ llPO139
REAR AXLE - Differential Carrier (Limited Slip Differential) 3-35
(3) Insert the special tool at the spline part of differential
case B (right) and check to be sure the side gear (right)
rotates.
(4) Then insert a 0.09 mm (.0035 in.) feeler gauge to
replace a 0.03 mm (0012 in.) gauge.
(5) Insert the special tool at the spline part of the
differential side gear (right) and check to be sure the
side gear (right) does not rotate.
Differential gear backlash
Standard value (clearance in thrust direction of side
gear):
0.03-0.09 mm (.0012-.0035 in.)
NOTE
If the clearance in the thrust direction of the side gear is
within the standard value range, the backlash of the
differential gear is normal.
(6) If the clearance in the thrust direction of the side gear is
not within the standard value range, remove differential
case A and make the adjustment by adjusting the
thickness of the thrust washer (left).
SERVICE POINTS OF DISASSEMBLY NO3lLBB
3. REMOVAL OF THE THRUST WASHER (LEFT)/

ferential side gear (right) Differential
9. THRUST WASHER (RIGHT)
The thrust washers (left and right) are of different thick-
ness, and so should be discriminated in some way for
reference during installation.
INSPECTION N03lMBB
(1) Check the gears and differential pinion shaft for unusual
wear or damage.
(2) Check the spline part of the differential side gear (right) for
Differential
pinion mate llPO12B
stepped wear or damage.
(3) Check the thrust washer and pinion mate washer for
Thrust washer Pinion mate unusual wear of contact surfaces, heat damage or other
damage.
Pinion mate
washer Thrust washer ,,po,29
1 (4) Check differential cases A and B for unusual wear of

Differential case B erentii contact surfaces, heat damage or other damage.
eA
0: Contact surface with the viscous unit
0: Contact surface with the pinion mate washer
@ and @I: Contact surfaces with thrust washer
11 PO131
3-36 REAR AXLE - Differential Carrier (Limited Slip Differential)
(5) Check the spline part of the viscous unit for stepped
Contact surface wear or damage, and check the contact surface with
with differential 45
differential case B.
(6) Check the side gear (left) of the viscous unit for unusual
wear or damage.
viscous unit
llPO142
SERVICE POINTS OF REASSEMBLY NOOINBE
ifferential case B 10. INSTALLATION OF THE DIFFERENTIAL CASE B/

2. DIFFERENTIAL CASE A
Ma Align the mating marks of differential cases B and A, and
ma assemble the cases.
1
6. INSTALLATION OF THE DIFFERENTIAL PINION MATE/
5. PINION MATE WASHER
Pinion mate
washer With the washer in the position shown in the figure, install
to the differential pinion shaft, and then install to differential M.
case B.
3. SELECTION OF THE THRUST WASHER (LEFT)
(1) If the differential side gear and pinion mate gear have
been replaced, select the thrust washer (left) by
b Difierential
following the steps below.
7 pinion mate
-
llPO134 @ Wash the differential side gear and pinion mate gear
in unleaded gasoline to remove all oil, grease, etc.
Feeler gauge @ Install the previously used thrust washers (being
careful the left and right ones are used at the
correct side), together with the gears, viscous unit,
pinion mate washer and pinion shaft, to differential
cases A and B, and then, using screws, secure
them temporarily.
@ Secure the differential case assembly in a vise so
that the differential side gear (right) is facing
upward.
Caution
When securing in the vise, be sure not to hold the
differential case assembly too tightly.
Feeler @I Insert a 0.03 mm LOO12 in.) feeler gauge at two
Feeler gauge
gauge
places (diagonally) between differential case B and
the thrust washer (right).
Caution
Do not insert a feeler gauge in the oil groove of rsr
differential case B.
Thrust washer (right)

lifferential gear (right)
, \ llPO130
REAR AXLE - Differential Carrier (Limited Slip Differential) 3-37
@ Insert the special tool at the spline part of differen-
tial side gear (right) and check to be sure the side
gear (right) rotates.
@I Then insert a 0.09 mm (0035 in.) feeler gauge to
replace a 0.03 mm (.0012 in.) gauge.
@ Insert the special tool at the spline part of the
differential side gear (right) and check to be sure the
side gear (right) does not rotate.
Differential gear backlash
Standard value (clearance in thrust direction of side
,> ..’ gear):
h
0 ,.,:* ~ ~ ,.;;s,
$.’ j
,
0 0.03-0.09 mm (.OOlZ-.0035 in.)
MB990990 NOTE
Feeler gauge ” Feeler If the clearance in the thrust direction of the side gear is
/ gauge within the standard value range, the backlash of the
differential side gear is normal.
@I If the clearance in the thrust direction of the side
gear is not within the standard value range, remove
differential case A and make the adjustment by
adjusting the thickness of the thrust washer (left).
Thrust washer (left)
Part No. Thickness mm (in.)
0.8 t.031)
0.9 f.035)
1 .o i.039)
1 .I ($043)
1 .15 (.045)
MB569243 1.2 LO471
1.25 (.049)
1.3 i.051)
1.35 (.053)
1.4 l.055)
1.5 i.059)
Thrust washer (right) (reference)
NOTE
Select one thrust washer (left) from the eleven types in the kit.
NOTES
BRAKES
SERVICE AND PARKING
CONTENTS
ANTI-LOCK BRAKING SYSTEM Front Brake Disc Run-out Check ................ 47

TROUBLESHOOTING ...................................... 9 Front Brake Disc Run-out Correction .......... 48
Front Brake Disc Thickness Check ............. 47
BRAKE BOOSTER ........................................... 60
Front Disc Brake Pad Check and
BRAKE LINE .................................................... 62 Replacement ................................................. 46
Parking Brake Lever Stroke Check ............. 42
BRAKE PEDAL ................................................. 53
Parking Brake Switch Check ....................... 43
ELECTRONIC CONTROL UNIT Proportioning Valve Function Test ............... 44
<VEHICLES WITH ABS> ............................... 87 Rear Brake Disc Run-out Check ................. 50
Rear Brake Disc Run-out Correction ........... 50
- FRONT DISC BRAKE ...................................... 65
Rear Brake Disc Thickness Check .............. 49
G-SENSOR <AWD-ABS> .............................. 86 Rear Disc Brake Pad Check and
Replacement ................................................. 48
HYDRAULIC UNIT
Observation of Wheel Speed Sensor
<VEHICLES WITH ABS> ............................... 77
Output Voltage Variations
<Vehicles with ABS> .................................. 51
MASTER CYLINDER ........................................ 56
SPECIAL TOOLS ............................................. 6
PARKING BRAKES .......................................... 88
REAR DISC BRAKE ......................................... 70 SPECIFICATIONS ............................................. 2

SERVICE ADJUSTMENT PROCEDURES.. ..... 41 Lubricants ...................................................... 5
ABS Power Relay Check ............................. 52 Service Specifications ................................... 4
Bleeding ........................................................ 45 Torque Specifications ................................... 4
Brake Booster Operating Inspection ........... 43
Brake Fluid Level Sensor Check ................. 42 TROUBLESHOOTING ...................................... 7
Brake Pedal Inspection and Adjustment ..... 41 WHEEL SPEED SENSOR
Check Valve Operation Check ..................... 44 <VEHICLES WITH ABS> ............................... 80
Flat Battery Remedy .................................... 52
_ CAUTION
When servicing brake assemblies or components, do not create dust by sanding, grinding or by cleaning
brake parts with a dry brush or with compressed air. A WATER DAMPENED CLOTH SHOULD BE USED.
Many brake components contain asbestos fibers which can become air-borne if dust is created during
service operations. Breathing dust which contains asbestos fibers can cause serious bodily harm.
5-2 BRAKES - SDecifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NO!iCA-- -
<Non-Turbo>
Items Vehicles without ABS Vehicles with ABS
N laster cylinder
Type Tandem type Tandem type
(with level sensor) (with level sensor)
I.D. mm (in.) 22.2 (7/8) 23.8 (‘%6)
BIrake booster
Type Vacuum type Vacuum type
Effective dia. of power cylinder mm (in.) 230 (9.0) Front side: 180 (7.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force] 5.0 [at 220 N (48 Ibs.)] 5.5 [at 220 N (48 Ibs.)]
Pl.oportioning valve
Type Dual type Dual type
Split point kPa (psi) 4,200 (597) 4,200 (597)
Decompression ratio 0.3 0.3
Fr ont brakes
Type Floating caliper, single-piston, Floating caliper, single-piston,
ventilated disc (M-R44V) ventilated disc (M-R44V)
Disc O.D. mm (in.) 256 (10.1) 256 (10.1)
Disc thickness mm (in.) 24 (.94) 24 (.94)
Pad thickness mm (in.) 16.0 (63) 16.0 (.63)
Wheel cylinder I.D. mm (in.) 53.9 (2 l/8) 53.9 (2%)
Clearance adjustment Automatic Automatic
3ar disc brakes

ventilated disc (AD30P) ventilated disc (AD30P)
Disc O.D. mm (in.) 265 (10.4) 265 (10.4)
Disc thickness mm ( i n . ) 10 (39) 10 i.39)
Pad thickness mm (in.) 14.5 (57) 14.5 (57)
Wheel cylinder I.D. mm ( i n . ) 3 0 . 1 (1 3/16) 30.1 (1 346)
Rc)tor teeth
Front wheel side - 47
Rear wheel side - 47
SPleed sensor - Magnet coil type

Pa rking brakes
Type Mechanical brake acting Mechanical brake acting
on rear wheels on rear wheels
Brake lever type Lever type Lever type
Cable arrangement V-type V-type
BRAKES - Specifications 5-3
<Turbo>
Items FWD AWD
Master cylinder
Type Tandem type Tandem type
(with level sensor) (with level sensor)
I.D. mm (in.) 23.8 (‘%a) 25.4 (1)
Brake booster
Type Vacuum type Vacuum type
Effective dia. of power cylinder mm (in.) Front side: 180 (7.0) Front side: 180 (7.0)
Rear side: 205 (8.0) Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force] 5.5 [at 220 N (48 Ibs.)] 5.5 [at 220 N (48 Ibs.)]
Proportioning valve
Type Dual type Dual type
Split point kPa (psi) 4,200 (597) 3,700 (526)
Decompression ratio 0.3 0.3
Front brakes
ventilated disc (M-R44V) ventilated disc (M-R46V)
Disc O.D. mm (in.) 256 (10.1) 256 (10.1)
Disc thickness mm (in.) 24 (.94) 24 (.94)
Pad thickness mm (in.) 16.0 (.63) 16.0 (.63)
Wheel cylinder I.D. mm ( i n . ) 53.9 (2 ‘16) 60.3 (23%3)
-.
Rear disc brakes

ventilated disc (AD30P) ventilated disc (AD35P)
Disc O.D. mm (in.) 265 (10.4) 265 (10.4)
Disc thickness mm (in.) 10 (.39) 10 f.39)
Pad thickness mm (in.) 14.5 (.57) 14.5 (.57)
Wheel cylinder I.D. mm (in.) 30.1 (1 3/16) 34.9 (1 3h)
qotor teeth*
Front wheel side 47 47
Rear wheel side 47 47
speed sensor* Magnet coil type Magnet coil type
‘arking brakes
Type Mechanical brake acting Mechanical brake acting
on rear wheels on rear wheels
Brake lever type Lever type Lever type
Cable arrangement V-type V-type
NOTE
The *symbol indicates vehicles with ABS.
5-4 BRAKES - Specifications
SERVICE SPECIFICATIONS NO5CB-
Standard value
Brake pedal height mm (in.) 176-181 (6.9-7.1)
Brake pedal free play m m ( i n . ) 3 - 8 (l-.3)
Brake pedal to floorboard clearance mm (in.) 80 (3.1) or more
Parking brake lever stroke 5-7 notches
Output pressure proportioning valve MPa (psi)
Split point
<FWD> 3.95-4.45 (561-633)
<AWD> 3.45-3.95 (491-561)
Output pressure [input pressure]
<FWD> 5.15-5.65 (732-804) [8.2 (1 ,I 63)l
<AWD> 4.65-5.15 (661-732) (7.7 (1,095)1
Disc brake dragging force at hub bolt
N (Ibs.) [Nm (ftlbs.)] 70 (15) or less [4 (3) or less1
Booster push rod to master cylinder piston clearance
mm (in.)
9 inch brake booster 0.8-l .O (.031-,039)
7 +8 inch brake booster 0.5-0.7 (.020-.028)
Speed sensor’s internal resistance kQ 0.8-l .2*
Clearance between the speed pole piece and
the toothed rotor m m ( i n . ) 0.3-0.9 (.012-,035)”
Limit
Left/right proportioning valve out pressure difference
MPa (psi) 0.4 (57)
Disc brake pad thickness mm (in.) 2.0 (08)
Front disc thickness mm (in.) 22.4 (882)
Rear disc thickness mm (in.) 8.4 (.331)
Disc runout mm (in.) 0.08 (.0031)
Hub end play mm (in.) 0.008 (.00031)
NOTE
*: Vehicles with ABS
Items Nm ft.lbs.
Pedal support bracket installation bolts 8-12 6-9
Pedal support bracket installation nut IO-15 7-11
Pedal rod to pedal support bracket 17-26 12-19
Pedal rod to clutch pedal bracket 17-26 12-19
Clutch pedal bracket installation bolt 8-12 6-9
Turn-over spring mounting bolt 17-26 12-19
Stop lamp switch mounting nut IO-15 7-l 1‘
Clutch master cylinder installation nuts 10-15 7-11
Clutch pedal installation nut 20-25 14-18
Lever assembly (A) installation nut 20-25 14-18
Lever assembly (B) installation nut 20-25 14-18
BRAKES - Specifications 5-5
Items Nm ftlbs.
Master cylinder to brake booster 8-12 6-9
Piston stopper bolt 1.5-3.0 l-2
Nipple installation screw 1.5-3.0 l-2
Brake booster installation nuts 11-17 8-12
Fitting 15-18 11-13
Flared brake line nuts 13-17 9-12
Brake hose bracket installation bolts 17-26 12-19
Front disc brake assembly installation bolts 80-100 58-72
Lock pin (front) 64-86 46-62
Guide pin (front) 64-86 46-62
Bleeder screw 7-9 5-7
Wheel bearing nut 200-260 144-188
Dust shield to axle beam 9-14 7-10
Rear disc brake assembly installation bolts 50-60 36-43
Drive shaft to companion flange 55-65 39-47
companion flange to rear axle shaft 160-200 116-159
Brake hose to caliper body (rear) 25-35 18-25
Lock pin (rear) 22-32 16-23
Guide pin (rear) 22-32 16-23
Spindle lever to parking brake lever 40-55 29-40
3ear speed sensor installation bolt 9-14 7-10
Speed sensor bracket installation bolt 9-14 7-10
3otor to front hub 7-11 5-8
3otor to rear hub 9-14 7-10
LUBRICANTS NO5CP-
Items Specified lubricant
Brake fluid MOPAR Brake Fluid/

Conforming to DOT3
Brake pedal bushing inner surface

Clevis pin and washer MOPAR Multi-mileage Lubricant
Parking brake lever sliding parts Part No. 2525035 or equivalent
Bushing inner surface
5-6 BRAKES - Specifications/Special Tools

Brake piston seal
Brake piston boot inner surfaces
Brake lock pin boot inner surfaces
Guide pin boot inner surfaces
Repair kit grease (orange)
Guide pin and caliper support contact surface
Lock pin and caliper support contact surface
Spindle lever, lever boot, connecting link,
O-ring and auto adjuster spindle
SPECIAL TOOLS
Rear disc brake Pressing of the rear disc brake pistons
Sliding hammer set

BRAKES - Troubleshooting
TROUBLESHOOTING
-
Brake drag
brake function
5-8 BRAKES - Troubleshooting
Scraping or grinding Worn brake pad Replace

noise when brakes are
applied Caliper to wheel interference
Correct or replace
Cracked brake disc
Squealing, groaning or Disc brakes-missing or damaged brake pad anti- Replace

chattering noise when squeak shim
brakes are applied
Brake discs and pads worn or scored
Correct or replace
Improper lining parts
Disc brake-burred or rusted calipers Clean or deburr
Dirty, greased, contaminated or glazed pad Clean or replace
Incorrect adjustment of brake pedal or booster Adjust
push-rod
Squealing noise when Disc brakes-rusted, stuck Lubricate or replace

brakes are not applied
Loose or extra parts in brakes Retighten
Improper positioning of pads in caliper

Correct
Improper installation of support mounting to caliper
body
Poor return of brake booster or master cylinder Replace

push-rod
Groaning, clicking or rat- Stones or foreign material trapped inside wheel Remove stones, etc.
tling noise when brakes covers
are not applied
Disc brakes-failure of shim Replace
Disc brakes-loose installation bolt

Retighten
Loose wheel nuts
push-rod
BRAKES - Anti-lock Braking System Troubleshooting 5-9
ANTI-LOCK BRAKING SYSTEM For problems in the electrical system, the self-
diagnosis function is built into the electronic control
-- TROUBLESHOOTING NO!JEBAE
unit (E.C.U.) causing the A.B.S. warning light to
PARTICULAR CHARACTERISTICS OF illuminate as a warning to the driver.
THE ANTI-LOCK BRAKING SYSTEM Problems in the hydraulic system (poor braking,
etc.) can be located in the same way as for ordinary
Models equipped with the anti-lock braking system brakes. There is, however, the necessity to check to
(A.B.S.) may exhibit one or more of the following determine whether the problem is related to ordin-
characteristics from time to time, but none of these ary brake components or to the components related
is abnormal. to the A.B.S.
(1) A pulsing feeling in the brake pedal, or vibration
of the body or the steering wheel, when the HOW TO USE THE TROUBLESHOOTING
anti-lock braking system is activated by sudden
braking or by braking on a slippery road surface.
FLOW CHART
Actually, this phenomenon is an indication that (1) Using the flow chart, check the ABS warning
the anti-lock braking system is functioning nor- light light-up sequence and check the condition
mally. of braking operation.
(2) When the vehicle speed reaches approximately (2) Following the check chart listed in the remedy
6 km/h (4 mph) after the engine is started and column, perform the checks. There are [Explana-
the vehicle starts off (for the first time), a tion] and [Hint] in each check chart. Refer to
whining motor noise may be heard from the them when troubleshooting.
engine compartment if the vehicle is traveling in NOTE
a quiet place, but this noise is simply the result ECU: Electronic control unit
of a self-check being made of the anti-lock HU: Hydraulic unit
braking system operation. MUT: Multi-use tester
TROUBLESHOOTING METHODS
Problems related to the anti-lock braking system
(A.B.S.) can be classified into two general categor-
ies: problems in the electrical system and those in
the hydraulic system.
5-10 BRAKES - Anti-lock Braking System Troubleshooting
TROUBLESHOOTING (ABS-FWD)
Confirm condition in the following way and diagnosis accordingly.
Ioes the ABS warning light illuminate as described ABS warning light remains lit because the valve
below up to the time the engine starts? relay is OFF.
1) When the ignition key is turned to the “ON” (3) When the ignition key is turned from the
position, the ABS warning light illuminates for “START” position to the “ON” position, the
approximately 1 second due to the ABS ECU (as ABS warning light illuminates for approximately
a self check of the valve relays is performed), 1 second (during this time a recheck of the valve
then it blinks twice and goes out and stays out. relays is performed), then it blinks twice and
2) With the ignition key in the “START” position, then goes out and stays out.
power to the ABS ECU is interrupted and the
1 sec. 1 sec. 1 sec.1 sec.
-- -
ABS warning ON I
light I
I
I
OFF
Ignition
ST
kev ON
3
ACC, LOCK 1
14AO589
1 I
Yes
CONTINUE TO NEXT PAGE No
No. Trouble condition

I Major causes Remedy
ABS warning light does not light up at all. l ABS warning light bulb is burnt out. Check, using flow
l Open in ABS warning light electrical chart A (Refer to P.5-
ON circuit (check for blown fuse) 12.)
1 --
ABS
warning
light
OFF
1
lgnitlon
kev
14A0590
When the ignition key is turned to the l Fail safe is functioning due to ECU self Check, using flow
“ON” position, it remains lighted. diagnosis chart B (Refer to P.5-
o Short in ECU warning light drive circuit 15.)
ABS l Malfunction of ECU
warning
light
2
Ignition
kev
ACC, LO:+
14AOSQl
Does not illuminate when ignition key is l Malfunction of valve relay Check, using flow
in “START” position. l Break in harness between ABS warn- chart C (Refer to P.5-
ing light and HU 17.)
ABS ON l Break in harness between HU and
warning
light body ground
3 OFF UUL
Ignition
kev A C C . LO:-+-
14A0592
./
No. Trouble condition Major causes Remedy
After the ignition key is turned to the l Break in harness for ECU warning Check, usin flow
“ON” position, it blinks once and then light drive circuit chart D. (Re9er to
illuminates when it is turned to the l Malfunction of ECU P.5-18.)
“START” position. When the key is
returned to the “ON” position, the light
4 blinks again. (Blinking with the ignition
key in the “ON” position is synchronized
with operation noise of the valve relay.)
ABS
warning
light o:-
Ignition
key ACC. LCi+-
14*0593
CONTINUED FROM PREVIOUS PAGE
Does the ABS warning light illuminate Yes ~ Trouble with the motor re- L Check, following trouble
when starting to drive the car? lay, solenoid valve [due to source check charts E-l -
self test when driving above E-6.
6 km/h (4 mph)] or malfunc-
1 tion of wheel speed sensor 1
No
Is there one-sided braking, insufficient

No Normal
braking force or malfunction of ABS
operation?
Yes
Trouble condition Major causes Remedy
One-sided braking l Mechanical lock of HU solenoid valve Check HU operation and, if

Insufficient braking force l Hydraulic line in HU is clogged. necessary, replace HU.
If HU is normal, check
Decline in ABS function l Malfunction in HU solenoid valve op- structural parts for normal
(Wheels easily lock when there is sud- eration braking. (Refer to P.5-7.)
den braking.) l Hydraulic line in HU is clogged.
ABS sometimes functions even when l Insufficient wheel speed sensor out- Check wheel speed sensor
there is no sudden braking. (ABS opera- put voltage (sensor malfunction, too ( R e f e r t o P.5-82.) and, if
tion vibration is transmitted.) large a gap between sensor rotor, necessary, replace sensor,
missing rotor teeth or temporarily adjust gap or replace rotor.
broken wire in sensor harness) If tests indicate that there are
l Malfunction of ABS ECU no mechanical or electrical
failures, replace the ECU.
A ABS warning light does not light at all. I_

[Explanation] [Hint]
When it does not liuht ULI at all, there is a strong If other warning lights do not light up either, fuse is
possibility that there is trouble with ABS warning probably blown.
light or with power to the light.
MAIN FUSIBLE IGNITION IGNITION

LINK @ SWITCH (IG2) SWITCH (IGl)
10A +,
.I
“2 6
-1 z
v ,,14
TO ABS I ” I
POWER Is&h ICOMBINAT~~N
ABS ECU
GND GNDGND
I v v v I
14AO596
No Check fuse No. 11. If it is
With the ignition key in the “ON” posi- l
tion, do other warning lights illuminate? blown, correct the cause of
I I
the blown fuse and then
replace the fuse.
Yes
No The harness between the

Does voltage between har-
ness connector terminal combination meter from
No. 14 and ground indicate ) fuse No.1 1 is broken.
battery voltage?
I
I
Yes Repair harness.
Circuit in combination meter Repair or replace com-

is broken. * bination meter.
( Turn the ignition switch OFF an

check.
I
Is the ABS warning light normal? (Check No L A&zed%rning l i g h t b u l b -
for burned bulb.)
Are instrument panel wiring harness, _ No ~ Connect connectors firmly.

engine compartment wiring harness, (Check for pins pulled out or
body wiring harness and ABS wiring bent, repair as needed.)
harness connectors connected properly?
drive circuits. Check and repair both

a Check ABS ECU.
No t Broken wire between ABS Repair harness.

Does the voltage between ECU harness
connector terminal No.25 and ground warning light and ECU
indicate battery voltage?
Yes Replace ABS ECU.
Check ABS valve relay.

I
<Remove valve relay and check. >
Is valve relay norm Replace valve relay.

I
Yes
Install the valve relay and, with the

(gnition k e y i n the “ O N ” position>
remove the HU connector and check.
I No
7 I I
Does voltage between the HU harness w Broken harness wire be- /---I1 Repair harness.
connetor terminal No.8 and ground indi- tween ABS warning light
cate battery voltage? and HU
Yes
Is there continuity between HU harness No* Broken harness wire be- Repair harness.
connector terminal No.9 and ground? tween HU and ground I
Yes
HU malfunction Replace HU.
B ABS warning light illuminated after the engine is started and remains on.
--
[Explanation]
This is the symptom when the ABS ECU does not system or when the warning light drive circuit is
power up due to broken ECU power circuit, etc., short circuited.
when the fail safe function operates and isolates the
MAIN IGNITION
FUSIBLE
LINK @I EYCH
z
A:7
J/B
Check, using check chart
0 E-l -E-6.
rb
10A
Check warning light drive

circuit.
t
Does the ABS warning light No Short in ECU transistor
remain illuminated even
with the ECU connector dis-
connected?
I
1 Yes IReplace
I
I
I 1
Does the ABS warning light
remain illuminated even
v
AI connected?
c: 2
3
! 127 Yes
r f
ABS ECU
I Replace HU or replace
valve relay. I
SUB IGNITION
FUSIBLE SWITCH
LINK @ W.2)
No - Correct cause of blown

fuse and replace fuse.
Yes
With the ignition key in the

“ON” position, does ,thf
E;;;; relay make a click
’
Disconnect ECU Yes ’
connector
and check harness connec-
tor.
Yes
I I 18
“ON” position, does voltage
between ECU connector ter-
I I
minal No. 18 and ground in- I
dicate the battery voltage?
1
I -
ABS ECU 9
1 Repair harness. I
---j-z-
SELF-DIAGNOSIS
CHECK Yes
CONNECTOR
Malfunction of ABS ECU Replace ABS ECU.

C ABS warning light does not illuminate when ignition key is in “START” position.
-.
[Explanation]
The ABS ECU uses the IG2 power source which is and the ECU turns the valve relay OFF. If the
turned off in the “START” position. The ABS warning light does not illuminate at this time, there
warning light uses the IGI power source which is is trouble in the warning light circuit on the valve
not turned off even in the “START” position. relay side.
Consequently, in the “START” position, power is off
MAIN IGNITION
FUSIBLE SWITCH
LINK @ (iG1)
I
J/B
between body connector
terminal No.8 and ground
indicate the battery voltage?
5 1 58 Yes
ABS ECU
D ABS warning light blinks once after the ignition key is turned to the “ON” position. It
illuminates in the “START” position and blinks once again when turned to the “ON” position.
[Explanation]
When power flows, the ABS ECU turns on the harness between the ECU and the warning light, the
warning light for approximately 1 sec. while it light illuminates only when the valve relay is off in
performs a valve relay test. If there is a break in the the valve relay test, etc.
connector and check with
I
In the ignition key “ON” _ No ~ Harness wire b e t w e e n
position, does voltage be- ABS warning light and
tween terminal No.25 and ECU is broken.
ground indicate battery vol-
tage?
Yes Repair harness.
125
t
ABS ECU
Malfunction of ABS ECU Replace ABS ECU.
El
14A0597
BRAKES - Anti-lock Braking System Troubleshooting 549
E-l Input abnormality of wheel speed sensor

-
I
The ABS ECU detects breaks in the wheel speed In addition to a broken wire/short circuit in the wheel
sensor wire. The warning light lights up if the wheel speed sensor, also check whether the sensor gap is
speed sensor signal is not input (or short circuited) too large, rotor teeth are missing, sensor harness
or if its output is low when starting to drive or while wire is temporarily broken, or sensor harness and
driving. body connector are not properly inserted.
I E-2 I Output abnormality of wheel speed sensor I

[Explanation]
The warning light lights up when there is an l When the sensor output signal is below the
abnormality (other than broken wire or short circuit) standard value or when amplitude modulation is
in the wheel speed sensor output signal while over the standard value, using an oscilloscope to
driving. measure the wave shape of the wheel speed
[Hint] sensor output signal is very effective.
l Loose wheel bearing
The following can be considered as the cause of the l Temporarily broken wire in sensor harness
wheel speed sensor output abnormality. l Sensor harness and body connector are not
l Distortion of rotor, teeth missing properly inserted.
l Low frequency noise interference when sensor
harness wire is broken NOTE
l Noise interference in sensor signal
If contact is poor, check the sensor cable by bending
and lightly stretching it.
SPEED SENSOR
FRONT REAR
(LEFT SIDE) (RIGHT SIDE) (LEFT SIDE) (RIGHT SIDE)
Km
I
ABS
ECU
I -.
I GND
I
I
I 24
I
I
FRONT SIDE
REVERSE SIDE
SELF-DIAGNOSIS
CHECK CONNECTOR
14AO601
5-20 _ BRAKES - Anti-lock Braking System Troubleshooting
Check flow connected with wheel speed NOTE:

sensor When checking with an oscilloscope, first measure voltage
variations in the wheel speed sensor output. (Refer to P.5-51.)
Is the resistance value of the wheel No c Malfunction of wheel speed Replace wheel speed
speed sensor part, which the displayed sensor sensor.
trouble code indicates, normal?
Standard value: 0.8-l .2 kQ
I Yes
Is the resistance value with the ECU No c H a r n e s s w i r e f o r w h e e l - Repair harness.
connector normal? speed sensor circuit is
I broken.
I 1
I
1
Is the standard value for the
gap between the wheel
speed sensor and rotor,
which the output trouble
code indicates, within the
range?
Standard value:
%Z~Pf!;!~~~e~
no missing or damaged
teeth?
1 Yes
1
Check the output of each
wheel speed sensor with an
oscilloscope, including the
wave form. (Refer to
measurement of wheel
speed sensor output voltage
variations on P.5-51 .I Is the
output voltage for each
wheel speed sensor over
the standard value and is the
wave form normal?
Yes
Can the abnormality be No

Repair harness.
found even if the sensor I
harness and connection be-
tween sensor harness and
body harness are bent and e
stretched?
Yes
BRAKES - Anti-lock Braking System Troubleshooting 5-g
E-3 Abnormality of stop light switch circuit

_ [Explanation] [Hint]
The ABS ECU turns on the warning light in the If the stop light operates normal, the ABS harness
following cases. wire for the stop light switch input circuit to the ECU
l Stop light switch may remain on for more than is broken or there is a malfunction in the ABS ECU.
15 minutes without the ABS functions.
l The harness wire for the stop light switch may
be open.
Do the stop lights light up No c Check the stop light re-

and go out normally? lated circuit and repair
I problem spots.
the ABS ECU

connector and inspect at
the harness side connec-
>
L N o Harness wire between

T AUTO- When the brake pedal is
pressed forcefullv, does the * stop light switch and ABS
voltage between’ connector ECU is broken.
terminal No. 29 and ground
J 1 Repair harness. I
Yes
TOP
IGHT
WITCH
I normal. l
Stop light switch circuit is
ABS
ECU
1 E-4 1 Abnormality of solenoid valve drive circuit

[Explanation]
The ABS ECU normally monitors the solenoid valve when turned OFF, the ECU determines the solenoid
drive circuit. coil wire is broken/short circuited or the harness is
If no current flows in the solenoid even if the ECU broken short circuited and then warning light lights
turns the solenoid ON or if it continues to flow even up.
Is the resistance value for

the solenoid valve, that the
No Replace HU. I
J/B
displayed trouble code indi-
cates, within the range of
the standard values?
Standard value: 3.0-3.2 Q
(
x
:OMBINATION ME:TER
No The harness wire for the

Is the solenoid valve resist-
ance value, that the output solenoid valve circuit
trouble code displays, within whose resistance value is
the range of the standard outside the range of the
values when measured at standard value is broken
the ECU connector? or short circuited.
Standard value: 3.0-3.2 B I
HU
1 Repair ABS harness.
nOrmll/
Solenoid valve drive circuit is
MA0603
E-5 Abnormality of valve relay drive circuit

~- [Explanation] Ii ;.
\jVhen the ignition switch is turned ON, the ABS normal. In addition, normally it monitors whether qr
ECU switches the valve relay OFF and ON for an not there is power in the valve power monitor line
initial check, compares the voltage of the signal to since the valve relay is normally ON. Then, if the
the valve relay and valve power monitor line voltage supply of power to the valve power monitor,line is
to check whether the valve relay operation is interrupted, the warning light illuminates.
IGNITION
MiN&USIBLE SWITCH
(IGI)
1
When the valve relay is Valve relay malfunction
checked, are the following
conditions found? I
No. 85-No. 86: resistance
value 60-120 Q
No. 30-No. 87a: continuity
No. 30-No. 87: No continui-
tY
When battery voltage is ap-
plied between terminals
No. 86 and No. 85 grounded.
No. 30-No. 87: continuity
No. 30-No. 87a: no continui-
Install the valve relay and

remove the HU connec-
ECU t the HU harnes

and remove the ECU con-
Is there continuity between

body connector terminal No.
22 and ground?
Yes
Valve relay drive circuit is
normal.
E-6 Abnormality of motor drive circuit

The ABS ECU illuminates the warning light for the If there is motor operation noise when wheel speed
motor relay and motor in the following cases. exceeds Gkm/h (4mph) when starting up after the
l When the motor relay does not function engine is started, there is a broken or short circuited
l When there is trouble with the motor itself and it motor monitor wire.
does not revolve
l When the motor ground line is disconnected and
the motor does not revolve
l When the motor continues to revolve Yes
Does the motor make a Broken wire or short cir-
noise when wheel speed cuit in motor monitor line
exceeds 6 km/h (4 mph)?
1
Repair the harness be-
tween HU and ECU.
, No
Remove the motor relay.
Remove the motor relay and

check resistance values.
value 30-60 52
No.30-No.87: no continui-
ty
Battery voltage is applied on
terminals No. 86 and No.85
grounded.
No.30-No.87: continuity
I Yes
Is pump motor ground con- No Connect ground wire.
netted normally?
I
lYes
motor relay and re-
move HU connector. >
Does voltage between body No c Broken wire i n p u m p

connector terminal 51 and motor power circuit
ground indicate battery vol- 4
tage?
Repair the harness.
Yes
14A0605
Is resistance between body No Malfunction of harness

connector terminal No. 2 and between HU and ECU
No.26 30-60 ohms? i
I I 1
Repair harness.
TROUBLESHOOTING (ABS-AWD)
Confirm condition in the following way and diagnosis accordingly.
C>oes the ABS warning light illuminate as described power to the ABS ECU is interrupted and the
relow up to the time the engine starts? ABS warning light remains lit because the valve
F1) When the ignition key is turned to the “ON” relay is OFF.
position, the ABS warning light illuminates for (3) When the ignition key is turned from the
approximately 1 second due to the ABS ECU (as “START” position to the “ON” position, the
a self check of the valve relays is performed), ABS warning light illuminates for approximately
then it blinks four times and goes out and stays 1 second (during this time a recheck of the valve
out. relays is performed), then it blinks four times
t:2) With the ignition key in the “START” position, and then goes out and stays out.
1 sec. 1 sec. 1 sec.1 sec.
IO1
- 14AO594
Yes
CONTINUE TO NEXT PAGE
No
ABS warning light does not light up at all. l ABS warning light bulb is burnt out. Check, using flow
l Open in ABS warning light electrical chart A. (Refer to P.5-
circuit (check for blown fuse) 27.)
ABS
warning OFF
light
1
Ignition
key ACC. LO;-+
14AOSSO
When the ignition key is turned to the l Fail safe is functioning due to ECU self Check, using flow
“ON” position, it remains lighted. diagnosis chart B. (Refer to P.5-
l Short in ECU warning light drive circuit 30.)
4BS l Malfunction of ECU
Naming
ight
2 0:7
gnition
w
ACC. LO:+
14A0591
Does not illuminate when ignition key is l Malfunction of valve relay Check, using flow
in “START” position. l Break in harness between ABS warn- chart C. (Refer to P.5-
ing light and HU 32.)
4BS ON l Break in harness between HU and
Naming
ight body ground
3 OFF
14A0595
After the ignition key is turned to the l Break in harness for ECU warning Check, using flow
“ON” position, it blinks once and then light drive circuit chart D. (Refer to P.5-
illuminates when it is turned to the l Malfunction of ECU 33.)
“START” position. When the key is
returned to the “ON” position, the light
4 blinks again. (Blinking with the ignition
key in the “ON” position is synchronized
with operation noise of the valve relay.)
ABS
warning
light 0:~
Ignition
key ACC. iv-
14A0593
CONTINUED FROM PREVIOU? PAGE
I ,
Yes
Does the ABS warning light illuminate L Trouble with the motor re- * Check, following trouble
when starting to drive the car? lay, solenoid valve [due to source check charts E-l -
self test when driving above E-7.
6 km/h (4 mph)] or malfunc-
tion of wheel speed sensor
No
Normal
Yes
Trouble condition Major causes Remedy
One-sided braking l Mechanical lock of HU solenoid valveCheck HU operation and, if

Insufficient braking force l Hydraulic line in HU is clogged. necessary, replace HU.
If HU is normal, check
Decline in ABS function l Malfunction in HU solenoid valve op- structural parts for normal
(Wheels easily lock when there is sud- eration braking. (Refer to P.5-2.)
den braking.) l Hydraulic line in HU is clogged.
ABS sometimes functions even when l Insufficient wheel speed sensor out- Check wheel speed sensor
there is no sudden braking. (ABS opera- put voltage (sensor malfunction, too (Refer to P.5-82.) and, if
tion vibration is transmitted.) large a gap between sensor rotor, necessary, replace sensor,
missing rotor teeth or temporarily adjust gap or replace rotor.
broken wire in sensor harness) If tests indicate that there are
l Malfunction of ABS ECU no mechanical or electrical
failures, replace the ECU.
A ABS warning light does not light at all.

I
-. [Explanation] [Hint]
When it does not light up at all, there is a strong If other warning lights do not light up either, fuse is
possibility that there is trouble with ABS warning probably blown.
light or with power to the light.
MAIN FUSIBLE IGNITION IGNITION

LINK @ SWITCH (IG2) SWITCH (IGI)
2
c-4
10A 10A p,
\I
*2 6
-I M"
7 ,,14 112131415161718
I 9 I
I. 0(1111211311915116117
iE4~oWER
#$II;NATION
58
m
2 ac
HU &,52 &8
--1
I I
I
I A x A ,c I
I 1~0~0~fWW-i VALVE " I
RELAY
1 IRELAY /--+I1 &- I I
I I \, J,. \ , I L
-1
I
-----------A
ABS ECU 1 25
GND GND
T7 ”
No Check fuse No.ll. If it is

With the ignition key in the “ON” posi-
tion, do other warning lights illuminate? blown, correct the cause of
the blown fuse and then
replace the fuse.
Yes
NO
Does voltage between har- The harness between the
ness
No. 14 and ground indicate ) fuse No.1 1 is broken.
battery voltage?
Yes
Circuit in combination meter Repair or replace com-

is broken. t bination meter. I
Turn the ignition switch OFF and

<check. >
I I I NO Replace ABS warning

Is the ABS warning light normal? (Check ) ABS warning light bulb
for burned bulb.) burned. * light bulb.
I
Yes
- N o
Are instrument panel wiring harness, c Connect connectors firmly.
engine compartment wiring harness, (Check for pins pulled out or
body wiring harness and ABS wiring bent, repair as needed.)
harness connectors connected properly?
Yes
Broken wire in ECU, valve relay or both

drive circuits. Check and repair both
circuits.
I
Yes HU malfunction Replace HU.

I
B ABS warning light illuminated after the engine is started and remains on.
[Explanation]
This is the symptom when the ABS ECU does not system or when the warning light drive circuit is
power up due to broken ECU power circuit, etc., short circuited.
when the fail safe function operates and isolates the
MAIN IGNITION
FUSIBLE SWITCH
LINK @ (IGl)
Check, using check chart

E-l -E-7.
Yes
Does the ABS warning light No Short in HU harness or

remain illuminated even m sticking of valve relay
with the ECU connector dis- contact
connected?
I
Yes
Replace HU or replace
valve relay.
ABS ECU
t
I
Short in harness between c Repair harness or replace
IT$Uhx ECU and ABS warning combination meter.
J
SUB IGNITION
%TB(kE zYCH
I Yes
1 ,
With the ignition key in the No _ Is power relay normal?
“ON” position, does the (Refer to P.5-52.)
power relay make a “click”:
noise?
L
Disconnect ECU connector Replace power relay.

and check harness connec-
IODE tor.
Yes

between ECU connector ter-
minal No. 18 and ground in-
dicate the battery voltage?
Yes
;LLF-FIAGNOSIS Yes
CONNECTOR
Replace ABS ECU.
C ABS warning light does not illuminate when ignition key is in “START” position.
[Explanation]
The ABS ECU uses the IG2 power source which is and the ECU turns the valve relay OFF. If the
turned off in the “START” position. The ABS warning light does not illuminate at this time, there
warning light uses the IGI power source which is is trouble in the warning light circuit on the valve
not turned off even in the “START” position. relay side.
Consequently, in the “START” position, power is off
MAIN IGNITION
FUSIBLE SWITCH hydraulic
LINK @I (IGl) unit (HU) connector and
\ />
I
J/B 1
“6 between body connector
2 11213141516l7l6 terminal No.8 and ground
I .14 191
1112113114115U6i,7 indicate the battery voltage?
9@ COMBINATION
AL METER
“58
No
Is there continuity between ~ Broken line between HU
body connector terminal and body ground
No.9 and ground?
I
Yes

HU connector terminal No. 8
and terminal No.9?
Yes
Remove the valve relay. Is

there continuity between
terminal No. 87a and No. 30?
I
Yes
1 Replace valve relay.
ABS ECU
HU harness malfunction
I
1 Replace HU.
1410000
D ABS warning light blinks once after the ignition key is turned to the “ON” position. It
*-_ illuminates in the “START” position and blinks once again when turned to the “ON” position.
[Explanation ]
When power flows, the ABS ECU turns on the harness between the ECU and the warning light, the
warning light for approximately 1 sec. while it light illuminates only when the valve relay is off in
performs a valve relay test. If there is a break in the the valve relay test, etc.
EC
Y connector and check with
4
x
l4 %4 \
\the harness connector. /
/
I
In the ignition key “ON”
9n. 58 position, does voltage be-
tween terminal No.25 and
ground indicate battery vol-
tage?
ABS ECU
Replace ABS ECU.
I
14A0597
E-l Input abnormality of wheel speed sensor

I.
[Explanation] [Hint] s”r
The ABS ECU detects breaks in the wheel speed In addition to a broken wire/short circuit in the wheel --
sensor wire. The warning light lights up if the wheel speed sensor, also check whether the sensor gap is
speed sensor signal RL is not input (or short too large, rotor teeth are missing, sensor- harness
circuited) or if its output is low when starting to drive wire is temporarily broken, or sensor harness and
or while driving. body connector are not properly inserted.
E-2 Output abnormality of wheel speed sensor

[Explanation]
The warning light lights up when there is an l When the sensor output signal is below the
abnormality (other than broken wire or short circuit) standard value or when amplitude modulation is
in the wheel speed sensor output signal while over the standard value, using an oscilloscope to
driving. measure the wave shape of the wheel speed
[Hinti sensor output signal is very effective.
l Loose wheel bearing
The following can be considered as the cause of the l Temporarily broken wire in sensor harness
wheel speed sensor output abnormality. l Sensor harness and body connector are not
l Distortion of rotor, teeth missing properly inserted.
l Low frequency noise interference when sensor
harness wire is broken NOTE
If contact is poor, check the sensor cable by bending
l Noise interference in sensor signal
and lightly stretching it.
SPEED SENSOR
FRONT REAR P%
(LEFT SIDE) (RIGHT SIDE) (LEFT SIDE) (RIGHT SIDE) ,’
FRONT SIDE
SELF-DIAGNOSIS
CHECK CONNECTOR 14AO608
Check flow connected with wheel speed NOTE:

sensor When checking with an oscilloscope, first measure voltage
fl-
variations in the wheel speed sensor output. (Refer to P.5-51.)
Is the resistance value of the wheel No c Malfunction of wheel speed _ ~ Replace wheel speed
speed sensor part, which the displayed sensor sensor.
trouble code indicates, normal?
Standard value: 0.8-l .2 kQ
Is the resistance value with the ECU No* Harness wire for wheel Repair harness.
connector normal? speed I
broken.
Is the standard value tor the

gap between the wheel
speed sensor and rotor,
which the output trouble
code indicates, within the
range?
Standard value:
h;ti;j3-0.9 m m (.012-
Rear Nb adjustment
- No
the wheel speed sensor . Replace rotor that has
rotor that the trouble code missing or damaged
indicates, normal and with teeth.
missing or damaged
No
Check the output of each
wheel speed sensor with an
oscilloscope, including the
w a v e f o r m . (Refewhekq
measurement of
speed sensor output voltage
variations on P.5-51.) Is the
output voltage for each
wheel speed sensor over
the standard value and is the
wave form normal?
Yes
I
Can the abnormality be Repair harness.
found even if the sensor
harness and connection be-
tween sensor harness and
body harness are bent and
stretched?
E-3 Abnormality of G sensor circuit

[Explanation]
The ABS ECU turns on the warning light in the
following cases.
l OFF trouble turning G sensor OFF (It is judged l When there is a broken wire or short circuit in
that the G sensor continues to be OFF for more the harness for the G sensor system.
than approximately 13 seconds except when the
Is G sensor normal? (Refer No Replace G sensor.

to P.5-86.)
I Yes
PlUN; F;SIBLE IGNITION

SWITCH (IG2)
J/B
With the ignition key “ON” _ No m The harness between the
does the voltage between G sensor and the ABS
terminal No.6 and ground ECU is broken.
I G sensor circuit is normal. I
G-SENSOR
E-l
ABS
ECU
14AO609
E-4 Abnormality of stop light switch circuit I

- [Explanation] [Hint]
The ABS ECU turns on the warning light in the If the stop light operates normal, the ABS harness
following cases. wire for the stop light switch input circuit to the ECU
l Stop light switch may remain on for more than is broken or there is a malfunction in the ABS ECU.
15 minutes without the ABS functions.
l The harness wire for the stop light switch may
be open.
Do the stop lights light up _ No c Check the stop light re-

and go out normally? lated circuit and repair
problem spots.
Yes
isconnect the ABS EC

connector and inspect at
the harness side connec-
tor.
No Harness wire between

AUTO-CRUISE When the brake pedal is
pressed forcefully, does the * stop light switch and ABS
voltage between connector ECU is broken.
terminal No. 29 and ground
indicate battery voltage? c
Repair harness.
Yes
STOP
LIGHT .
SWITCH
;gSJ;ght switch circuit is
STOP 0.85-G ’
LIGHT
w
--I
RESIS-
TOR
ABS
ECU
14AO610
E-5 Abnormality of solenoid valve drive circuit

[Explanation] *>
The ABS ECU normally monitors the solenoid valve when turned OFF, the ECU determines the solenoid %’ -’
drive circuit. coil wire is broken/short circuited or the harness is
If no current flows in the solenoid even if the ECU broken/short circuited and then the warning light
turns the solenoid ON or if it continues to flow even lights up.
tor and check with the

side connector.
IGNITION
SWITCH
(IGI)
1 No
7 Is the resistance value for Replace HU.
the solenoid valve within the I
range of the standard
JIB values?
Standard value: 3.0-3.2 Q
J
, IYes ,
Connect HU 1OP connec-

disconnect ECU con-
>
Is the solenoid valve resis-

No The harness wire for the
tance value within the range solenoid valve circuit ,-
of the standard values when whose resistance value is
measured at the ECU con- outside the range of the ‘he-
nector? standard value is broken

Standard value: 3.0-3.2 Q or short circuited.
------_-_
Yes
-Repair
1
I I
I Solenoid valve drive circuit is

normal. I
E-6 Abnormality of valve relay drive circuit
I
j-a [Explanation]
When the ignition switch is turned ON, the ABS normal. In addition, normally it monitors whether or
ECU switches the valve relay OFF and ON for an not there is power in the valve power monitor line
initial check, compares the voltage of the signal to since the valve relay is normally ON. Then, if the
the valve relay and valve power monitor line voltage supply of power to the valve power monitor line is
to check whether the valve relay operation is interrupted, the warning light illuminates.
IGNITION
MAIN FUSIBLE SWITCH
LINK @ W-31)
No Valve relay malfunction

When the valve relay is
checked, are the following
conditions found?
No.85-No.86: resistance
value 60-120 Q Replace valve relay.
No.30-No.87a: continuity I
No.30-No.87: No continui-
When battery voltage is ap-
plied between terminals
No.86 and No. 85 grounded.
No. 30-No. 87a: no continui-
ty
remove the HU connec-
Connect the HU
remove the ECU con-
I Yes
I Valve relay drive circuit is

normal. I
E-7 Abnormality of motor drive circuit

The ABS ECU illuminates the warning light for the If there is motor operation noise when wheel speed
motor relay and motor in the following cases. exceeds Gkm/h (4mph) when starting up after the
l When the motor relay does not function engine is started, there is a broken or short circuited
l When there is trouble with the motor itself and it motor monitor wire.
does not revolve
l When the motor ground line is disconnected and
the motor does not revolve
l When the motor continues to revolve
Does the motor make a Yes Broken wire or short cir-
noise when wheel speed - cuit in motor monitor line
exceeds 6 km/h (4 mph)? b
No Repair the harness be
tween HU and ECU.
emove the motor rela
Remove the motor relav and q Motor relay malfunction 1

check resistance values.
value 30-60 Q Replace motor relay.
No.30-No.87: no continui- I
ty
Battery voltage is applied on
terminals No. 86 and No. 85
grounded
Yes
Is pump motor ground con- Connect ground wire.
netted normally? I
b
Does voltage between body I No Broken wire in pump
connector terminal 51 and motor power circuit
ground indicate battery vol- 1
ABS ECU tage?
Repair the harness.
Yes
14A0105
Is resistance between body - No L Malfunction of harness
connector terminal No. 2 and between HU and ECU
No.26 30-60 ohms? b
Yes Repair harness.
Motor drive circuit is normal.
BRAKES - Service Adjustment Procedures 5-47
BRAKE PEDAL INSPECTION AND ADJUSTM&g
switch
1. Measure the brake pedal height as illustrated. If the brake
switch pedal height is not within the standard value, adjust as
follows.
Standard value (A): 176181 mm (6.9-7.1 in.)
v 14F516
(1) Disconnect the stop light switch connector, loosen the

lock nut, and move the stop light switch to a position
I d o w n ,./ where it does not contact the brake pedal arm.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) After screwing in the stop light switch until it contacts
the brake pedal stopper (just before the brake pedal is
caused to move), return the stop light switch l/2 to 1
turn and secure by tightening the lock nut.
(4) Connect the connector of the stop light switch.

(5) Check to be sure that the stop light is not illuminated
with the brake pedal unpressed.
Reference value (B): 0.5-1.0 mm (.02-M in.)
2. With the engine stopped, depress the brake pedal two or

F14517
three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value (C): 3-8 mm (.l-.3 in.)
If the free play is less than the standard value, confirm that
the clearance between the stop light switch and brake
pedal is within the standard value.
If the free play exceeds the standard value, it is probably
due to excessive play between the clevis pin and brake
pedal arm. Check for excessive clearance and replace
F14518 faulty parts as required.
3. Start the engine, depress the brake pedal with approxi-
mately 500 N (110 Ibs.) of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value (D): 80 mm (3.1 in.) or more
If the clearance is less than the standard value, check for
air trapped in the brake line and for brake fluid leaks. If
necessary, check the brake system mechanism (excessive
shoe clearance due to faulty auto adjuster) and repair
faulty parts as required.
F14519
5-42 BRAKES - Service Adjustment Procedures
BRAKE FLUID LEVEL SENSOR CHECK NO5FBAB
(1) Connect a circuit tester to the brake fluid level sensor. 4

(2) Move the float from top to bottom and check for .-,’
continuity.
(3) The brake fluid level sensor is in good condition if there is
no continuity when the float surface is above “A”, and if
there is continuity when the float surface is below “A”.
PARKING BRAKE LEVER STROKE CHECK NWFEAJ
1. Pull the parking brake lever with a force of approx. 200 N

(45 Ibs.), and count the number of notches.
Caution
The 200 N (45 Ibs.) force of the parking brake lever must
be strictly observed.
Standard value: 5-7 notches
2. If the parking brake lever stroke is not the standard value,

adjust as described below.
(1) Remove the carpet in the floor console.
(2) Loosen the adjusting nut to the end of the cable rod, fi
thus freeing the parking brake cable.
(3) With the engine idling, firmly depress the brake pedal
five or six times and confirm that the pedal stroke stops
changing.
NOTE
If the pedal stroke stops changing, it indicates that the
automatic adjusting mechanism has functioned proper-
ly to adjust the clearance between the pads and the
disc to the correct value.
(4) Check to be sure that the clearance between the

stopper and the parking brake lever at the caliper side is
as shown in the figure.
NOTE
If the clearance between the parking brake lever and
the stopper exceeds 2 mm (078 in.), the probable
causes are brake cable sticking, improper wiring, or a
malfunction of the automatic adjuster (within the rear
brake caliper), so it is necessary to check the parking -
brake cable and to disassemble and check the rear -
brake caliper.
(5) Turn the adjusting nut to adjust the parking brake lever
stroke to within the standard value range.
Caution
If the number of brake lever notches engaged is less
than the standard value, the cable has been pulled
excessively, and failure of the automatic adjuster
mechanism will result. Be sure tti adjust it to within the
standard value.
(6) After making the adjustment, check to be sure that there is

no play between the adjusting nut and the pin. Also check
to be sure that the adjusting nut is securely held at the nut
holder.
(7) After adjusting the lever stroke, jack up the rear of the
vehicle.
(8) With the parking brake lever in the released position, turn
the rear wheel to confirm that the rear brakes are not
dragging.
PARKING BRAKE SWITCH CHECK N05FDAB
(1) Disconnect the connector of the parking brake switch, and

connect an ohmmeter to the parking brake switch and the
switch installation bolt.
(2) The parking brake switch is good if there is continuity when
the parking brake lever is pulled and there is no continuity
0wtwo061
when it is returned.
BRAKE BOOSTER OPERATING lNSPECTIONNoSFcu
For simple checking of brake booster operation, carry out the
following tests.
(1) Run the engine for one or two minutes, and then stop it.
No good
(2) Step on the brake pedal several times with normal
pressure.
If the pedal depressed fully the first time. but gradually
becomes higher when depressed succeeding times, the
booster is operating properly.
If the pedal height remains unchanged, the booster is
faulty.
(3) With the engine stopped, step on the brake pedal several
times with the same pressure to make sure that the pedal
height will not change.
Then step on the brake pedal and start the engine.
When engine is VV;Videngine is If the pedal moves downward slightly, the booster is in
stopped good condition. If there is no change, the booster is faulty.
(4) With the engine running, step on the brake pedal and then
stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is faulty.
If the above three tests are okay, the booster performance can
be determined as good.
If one of the above three tests is not okay at last, the check
t4uoo60 valve, vacuum hose, or booster will be faulty.
BRAKES - Service Adjustment Procedures
CHECK VALVE OPERATION CHECK NOSFNAJ
When checking the check valve, keep the check valve fit in the
vacuum hose.
1. Remove the vacuum hose.
Caution
The check valve is press-fit inside the vacuum hose and
do not remove the check valve from the vacuum hose.
2. Check the operation of the check valve by using a vacuum

pump.
Vacuum pump connection Accept/reject criteria
Connection at the brake A negative pressure (vacuum) is

booster side @I created and held.
Connection at the intake A negative pressure (vacuum) is not

manifold side @ created.
Caution
If the check valve is defective, replace it as an assembly
WA041 7
unit together with the vacuum hose.
Pressure PROPORTIONING VALVE FUNCTION TEST NOSFKAJ
gauge Pressure 1. Connect two pressure gauges, one each to the input side
and output side of the proportioning valve, as shown.
2. Air bleed the brake line and the pressure gauge.
3. While gradually depressing the brake pedal, make the
following measurements and check to be sure that the
measured values are within the allowable range.
(1) Output pressure begins to drop relative to input
pressure (split point).
PropG-tioning valve t4Lmt
Standard value:
<PWD> 3.95-4.45 MPa (561-633 psi)
<AWD> 3.45-3.95 MPa (491-561 psi)
,’
(2) Output fluid pressure when input fluid pressure are as
, Sdit point
follows.
Standard value:
output tFVVD> 5 . 1 5 - 5 . 6 5 MPa (732-804 psi)
pressure [at 8.2 MPa (1,163 psi)]
<AWD> 4.65-5.15 MPa (661-732 psi)
[at 7.7 MPa (1,095 psi)],
(3) Output pressure difference between left and right
Input pressure
brake lines
14uoo55
Limit: 0.4 MPa (57 psi)
4. If the measured pressures are not within the permissible
ranges, replace the proportioning valve.
BRAKES - Service Adiustment Procedures 5-45
BLEEDING N65FYAN
When the master cylinder is empty of brake fluid, bleed air

from the master cylinder by proceeding with procedures (1)
thru (6). (Because this master cylinder is not equipped with a
check valve.)
When brake fluid remains in the master cylinder, proceed with
step (6).
(1) -Disconnect the brake tube from the master cylinder.
(2) Two persons should conduct the air bleeding, one person
slowly depressing the brake pedal and holding the pedal
depressed.
(3) In this condition, the other person should use a finger to
close the outlet part of the master cylinder, and then the
first person should release the brake pedal.
(4) Steps (2) and (3) should be repeated three or four times,
and then the master cylinder should be filled with brake
fluid to the specified level.
NOTE
The air is completely bled from the master cylinder by steps
(1) to (4).
(5) Connect the brake tube to the master cylinder.
I \ \ 14A0416
(6) Start the engine; then, in the sequence shown in the
illustration, bleed the air from each wheel cylinder.
Specified brake fluid: MOPAR Brake Fluid/
Conforming to DOT3
Caution
1. Use the specified brake fluid. Avoid using a mixture
of the specified brake fluid and other fluid.
2. If brake fluid is exposed to the air, it will absorb
moisture; as water is absorbed from the atmos-
phere, the boiling point of the brake fluid will
2 3 decrease and the braking performance will be
14A04.54
seriously impaired. For this reason, use a hermeti-
cally sealed 1 lit. (1.06 qt.) or 0.5 lit. (0.52 qt.) brake
fluid container.
3. Firmly close the cap of the brake fluid container
after use.
4. For vehicles with the anti-lock braking system, be
sure to install a filter to the master cylinder
reservoir tank when supplying brake fluid.
ORDINARY AIR-BLEEDING PROCEDURES

(1) Depress the brake pedal several times until resistance is
felt; then, with the pedal depressed, loosen the bleeder
screw l/3 to l/2 turn and then tighten it before the fluid
pressure is all gone.
(2) Release the brake pedal. Repeat this procedure until there
are no more air bubbles in the brake fluid.
When new When worn FRONT DISC BRAKE PAD CHECK AND REPLACE-
MENi NWFOAF
NOTE
The brake pads have wear indicators that contact the brake disc d’
when the brake pad thickness becomes 2 mm (.08 in.), and
emit a squealing sound to warn the driver.
14G0017
1. Check brake pad thickness through caliper body check

port.
Limit: 2.0 mm (.08 in.)
Caution
1. When the limit is exceeded, replace the pads at
both sides, and also the brake pads for the wheels
on the opposite side at the same time.
2. If there is a significant difference in the thicknesses
of the pads on the left and right sides, check the
14LO169
sliding condition of the piston, lock pin sleeve and
guide pin sleeve.
2. Remove lock or guide pin. Lift caliper assembly and retain
with wires.
Caution
Do not wipe off the special grease that is on the guide -
pin or allow it to contaminate the guide pin.
3. Remove the following parts from caliper support.

=Qg@-(4)
(1) Pad and wear

indicator assembly
(2) Pad assembly
(3) Outer shim
(4) Pad clips
14A0403
-
4. Measure hub torque with pad removed to measure brake
drag torque after pad installation.
NOTE
Tighten the nuts in order to secure the disc to the hub.
5. Securely attach the pad clip to the caliper support. a
\ 14AO400
6. Clean piston and insert into cylinder with tool.
7. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin.
8. Check brake drag torque as follows.

(1) Start engine and hold brake pedal down for 5 seconds.
(2) Stop engine.
(3) Turn brake disc forward 10 times.
(4) Check brake drag torque with spring scale.
If the difference between brake drag torque and hub torque
exceeds the standard value, disassemble piston and clean
the piston. Check for corrosion or worn piston seal, and
check the sliding condition of the lock pin and guide pin.
Standard value: 70 N (15 Ibs.) or less
14AO399
-
[4 Nm (3 ftlbs.)] or less
FRONT BRAKE DISC THICKNESS CHECK NQ5FRAS
Remove dirt and rust from brake disc surface. Measure disc
thickness at 4 locations or more.
Limit: 22.4 mm (.882 in.)
Replace the discs and pad assembly for both sides left and
right of the vehicle if they are worn beyond the specified limit.
FRONT BRAKE DISC RUN-OUT CHECK NOIFSAB
1. Remove the caliper support; then raise the caliper assem-

bly upward and secure by using wire.
2. Place a dial gauge approximately 5 mm (2 in.) from the

outer circumference of the brake disc, and measure the
run-out of the disc.
Limit: 0.08 mm (.0031 in.)
NOTE
FRONT BRAKE DISC RUN-OUT CORRECTIO&wAB

1. If the run-out of the brake disc is equivalent to or exceeds 5
the limit specification, change the phase of the disc and -’
hub, and then measure the run-out again.
(1) Before removing the brake disc, chalk both sides of the
wheel stud on the side at which run-out is greatest.
(2) Remove the brake disc, and then place a dial gauge as
shown in the illustration; then move the hub in the axial
direction and measure the play.
Limit: 0.008 mm (00031 in.)
If the play is equivalent to or exceeds the limit,
disassemble the hub knuckle and check each part.
(3) If the play does not exceed the limit specification, and
then check the run-out of the brake disc once again.
Mount the brake disc on the position dislocated from
the chalk mark. ei
2. If the run-out cannot be corrected by changing the phase-of I’
the brake disc, replace the disc.
14A0407
REAR DISC BRAKE PAD CHECK AND REPLACE-

MENT NO5FUAD
1. Check brake pad thickness through caliper body check

port.
Limit: 2.0 mm (.08 in.)
Caution
1. When the limit is exceeded, replace the pads at
both sides, and also the brake pads for the wheels
on the opposite side at the same time.
2. If there is a significant difference in the thicknesses
of the pads on the left and right sides, check the
sliding condition of the piston, lock pin sleeve and
guide pin sleeve.
2. Loosen the parking brake cable (from the vehicle interior),
and disconnect the parking brake end installed to the rear
brake assembly. A
3. Remove lock pin. Lift caliper assembly and retain with -‘
wires.
Caution
Do not wipe off the special grease that is on the lock
pin or allow it to contaminate the lock pin.
4. Remove the following parts from caliper support.
Outer shim
Pad assembly
Pad clips C
Pad clips B
MAO204
14AO405
5. Measure hub torque with pad removed to measure brake

drag torque after pad installation.
NOTE
To secure the disc to the hub, tighten the nuts.
6. Securely attach the pad clip to the caliper support.
Caution
Do not deposit grease or other dirt on pad or brake disc
friction surfaces.
14AOs
7. Clean the piston; then use the special tool to thread the
piston into the cylinder.
Be sure, at this time, that the stopper groove of the piston
correctly fits to the projection on the pad’s rear surface.
8. Be careful that the piston boot does not become caught,
grooves when lowering the caliper assembly and install the lock pin.
Q
0 0
Projection
14R0037
With the engine running, forcefully depress the brake pedal
five or six times, and then check whether or not the stroke
of the parking brake lever is within the standard value.
If there is a deviation from the standard value, adjust the
stroke of the parking brake lever.
(Refer to P.5-42.)
9. Check brake drag torque as follows.
(2) Stop engine.
piston. Check for corrosion or worn piston seal, and check
the sliding condition of the lock pin sleeve and guide pin
sleeve.
14A0401 Standard value: 70 N (15 Ibs.) or less
[4 Nm (3 ft.lbs)] or less
REAR BRAKE DISC THICKNESS CHECK NOSWAB
1. Remove dirt and rust from brake disc surface.

2. Measure disc thickness at 4 locations or more.
Limit: 8.4 mm (.331 in.)
Replace the discs and pad assembly for both sides left and
right of the vehicle if they are worn beyond the specified
limit.
14AO406
5-50 BRAKES - Service Adiustment Procedures
REAR BRAKE DISC RUN-OUT CHECK NOSWAB
1. Remove the caliper support, raise the caliper assembly, and Ir.
secure it by using a wire, etc. -u /
14A.0067
2. Place a dial gauge approximately 5 mm (2 in.) from the

outer circumference of the brake disc, and measure the
run-out of the disc.
Limit: 0.08 mm (.0031 in.)
NOTE
To secure the disc to the hub, tighten the nuts.
MAO409
-
REAR BRAKE DISC RUN-OUT CORRECTION NWFXAA
1. If the run-out of the brake disc is equivalent to or exceeds

the limit specification, change the phase of the disc and
hub, and then measure the run-out again. rc
NOTE
The procedures for checking by changing the installation
phase of the disc are the same as those for the front brake
discs. (Refer to P.5-48.)
2. If the problem cannot be corrected by changing the phase
of the brake disc, replace the disc.
OBSERVATION OF WHEEL SPEED SENSOR
OUTPUT VOLTAGE VARIATIONS
<Vehicles with ABS> N65FOAO
(1) Jack up the vehicle and release the parking brake.

(2) Disconnect the electronic control unit harness connector,
and measure the speed sensor output voltage at the
vehicle side harness connector.
(3) With an AWD model, put the shift lever in 1st (MTT) or L
(A/T) position, rotate the wheels and observe the wave
shape for each wheel. With an FWD model, put the shift
lever in 1st (M/T) or L (AiT) position, rotate the wheels and
observe the wave shape for the front wheels; for the rear
E.C.U. terminal
wheels, rotate the wheels by hand and monitor the wave
shape.
NOTE
It is also allright to actually drive the car.
I Speed sensor E.C.U. terminal No. I

I Front left I 14-15 I
I Front right 31-33 I

I
I Rear right 28-30 I
I Rear left 1 10-11 I
When wheel speed is slow, the output voltage is low

and it gets higher as the speed increases.
Low gear idle condition Wave shape monitoring points

[Speed: 5-6 km (3.1-3.16 mph)] IS THE OUTPUTVOLTAGE (AMPLITUDE) TOO LOW OR IS
THERE NO OUTPUT VOLTAGE?
If it is too low, check each wheel speed sensor,
With FWD rear wheels, check the sensor gap.
IS THERE VARIATION IN THE WAVE SHAPE AMPLITUDE?
If the flicker of the amplitude is large, consider shaking
Approx. 5V
of the axle hub.
IS THERE NOISE IN THE WAVE SHAPE OR DISTORTION?
Broken or disconnected wire due to vibration or
14A0580 installation malfunction of the wheel speed sensor.
Check rotor teeth meshing, breaks, etc.
When increasing speed
[Speed: 15-20 km (9.3-12.4 mph11
Approx. 1 OV
14A0501
ABS POWER RELAY CHECK NO5FOAN
(1 ) Remove the ABS power relay from the ABS control unit q
bracket. -/
(2) Connect battery to terminal 2 and check continuity

between terminals with terminal 4 grounded.
Power is supplied l-3 terminals Continuity
Power is not 1-3 terminals No continuity

supplied 2-4 terminals Continuity
A
I
16LO312 lOWOO
FLAT BATTERY REMEDY NOWOAF
When booster cables are used to start the engine when the
battery is completely flat and then the vehicle is immediately
driven without waiting for the battery to recharge itself to some
extent, the engine may misfire, and driving might not be
possible. This happens because ABS consumes a great
amount of current for its self-check function; the remedy is to
either allow the battery to recharge sufficiently, or to discon-
nect the connector for ABS circuit, thus disabling ABS.
The ABS warning light will illuminate when the connector (for
ABS) is disconnected.
After the battery has sufficiently charged, connect the connec-
tor (for ABS) and restart the engine; then check to be sure the
ABS warning light is not illuminated.
BRAKES - Brake Pedal 5-53
BRAKE PEDAL
-I REMOVAL AND INSTALLATION NO5OA--

aRemoval of Knee Protector l installation of Relay Box (Indoor)
(Refer to GROUP 23%Instrument Panel.) l Installation of Steering Column Assembly and
ORemoval of Lap Cooler Duct and Shower Column Support
Duct (L.H.) (Refer to GROUP 19-Steering Wheel and
(Refer to GROUP 23-Instrument Panel.) Shaft.)
l Removal of Steering Column Assembly and @Installation of Lap Cooler Duct and Shower
Column Support <MTT> Duct (L.H.)
(Refer to GROUP 19-Steering Wheel and (Refer to GROUP 23-Instrument Panel.)
Shaft.) l Installation of Knee Protector
*Removal of Relay Box (Indoor) (Refer to GROUP 23-Instrument Panel.)
aBrake Pedal Adjustment
(Refer to P.5-41.)
20-25 Nm
,‘14-18 ft.lbs.
<A/T> .20
6 - 9 ftlbs.
IO-15 Nm /
7 - 1 1 ft.lbs.
/
11-17 Nm
8-12 ftlbs.
14A0525
Removal steps 21. Lever

1. Stop light switch connector 22. Pedal support bracket
2. Stop light switch 24. Lever assembly (A)
l + 5. Return spring 25. Bushing
9. Cotter pin l * 26. Pedal rod
10. Washer 27. Bushing
11. Clevis pin 28. Brake pedal
12. Cotter pin 29. Lever assembly(B) mounting nut
. 13. Shift-lock cable connection 30. Lever assembly (B)
20. Lever assembly (A) mounting nut 31. Bushing
NOTF
(i, Reverse the removal procedures to reinstall.
(2) 4I) : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service Points of Installation”.
(5) * : Vehicles with auto-cruise control system
5-54 BRAKES - Brake Pedal
<M/T>
IO-15 Nm 20-25 Nm
7 - 1 1 ft.lbs. 14-18 ft.lbs.
I
\
17-26 Nm
12-19 ft.lbs.
1
8-12 Nm
- 6-9 ft.lbs.
- /-
11 7 - 1 1 ft.lbs.
Removal steps 14AG451
Stop light switch connector 13

Stop light switch Brake booster push rod
Clutch switch connector and clutch switch
Inter lock switch connector 1:: Pedal and bracket assembly
Return spring 16. Clutch pedal mounting nut
Lever assembly
Return spring <Non-Turbo>
Clip <Turbo> 1:: Clutch pedal bracket
19. Inter lock switch
Turn over spring <Turbo>
Cotter pin 22. Pedal support bracket
Washer 23. Clutch pedal
Clevis pin W 25. Bushing
4* 26. P,;$;d
I)4 27.
28. Brake pedal
Fyfeverse the removal procedures to reinstall.

# m : Non-reusabje p a r t s
* : Vehicles with auto-cruise control system
SERVICE POINTS OF REMOVAL NO5GBAHa
26. REMOVAL OF PEDAL ROD

Using a plastic hammer, remove the pedal rod from t h e
pedal support bracket.
BRAKES - Brake Pedal 5-55
INSPECTION NoMicAl
l Check the bushing for wear.

l Check the brake pedal for bend or twisting.
l Check the brake pedal return spring for ‘damage.
Stop light switch
Connect a circuit tester to the stop light switch, and check
whether or not there is continuity when the plunger of the’stop
light switch is pushed in and when it is released.
14L0142 The stop light switch is in good condition if there is no
No continuity Continuity continuity when the plunger is pushed in to a depth of within 4
mm (.I6 in.) from the outer case edge surface, and if there is
continuity when it is released.
For vehicles with the auto-cruise control system, the check for
mm t.16 in.) continuity should be made at connectors “a” and “b” of the
stop light switch.
14LO171
:Vehicles with auto-cruise
ontrol svstem>
SERVICE POINTS OF INSTALLATION N05GDBAa
27.125. APPLICATION OF GREASE TO BUSHING

Apply a coating of the specified grease to the inner surface
of the bushings.
14A0256
11. APPLICATION OF GREASE TO CLEVIS PIN/ IO.

WASHER
After applying the specified grease to the clevis pin and
washer, insert the clevis pin and bend the cotter pin tightly.
8. INSTALLATION OF TURN OVER SPRING <TURBO>
Refer to GROUP 6-Clutch pedal.
14ll0050
6.15. INSTALLATION OF RETURN SPRING

Install the return spring in the direction indicated in the
illustration.
5-56 BRAKES - Master Cylinder
MASTER CYLINDER
l Draining of Brake Fluid l supplying Brake Fluid
l Bleeding
(Refer to P.5-45.1
l Adjustment of Brake Pedal
(Refer to P.5-41.)
/ 14A0249
8-12 Nm
6-S Mbs.
Removal steps
1. Fluid level sensor connector
2. Brake tubes
3. Reservoir hoses
4. Master cylinder
5. Reservoir
6. Bracket NOTE
l 4 Adjustment of clearance between brake (I) Reverse the removal procedures to reinstall.
booster push rod and primary piston (2) l + : Refer to “Service Points of Installation”.
SERVICE POINTS OF INSTALLATION NWlDAOa
. ADJUSTMENT OF CLEARANCE BETWEEN BRAKE

BOOSTER PUSH ‘ROD AND PRIMARY PISTON
Adjust the clearance (A) between the brake booster push m
rod and primary piston as follows: J
14110053
BRAKES - Master Cylinder 5-57
(1) Measure the dimension (B) between the master cylinder
end face and piston.
NOTE
To obtain (B), first take measurement with a square placed
on the master cylinder end face. Then, subtract the
thickness of the square to arrive at (B).
14110064
(2) Obtain the dimension (C) between the brake booster

mounting surface on the master cylinder and the end face.
14110065
(3) Measure the dimension (D) between the master cylinder

mounting surface on brake booster and the push rod end.
NOTE
To obtain (D), first take measurement with a square placed
on the brake booster. Then, subtract the thickness of the
square to arrive at (D).
(4). Using the measured values obtained in (1) through (3),
obtain the clearance (A) between the brake booster push
rod and primary piston.
Standard value: [A (A = B-C-D)]
9 inch brake booster
0.8-1.0 mm (.031-.039 in.)
7 +8 inch brake booster
0.5-0.7 mm (.020-.028 in.)
(5) If the clearance is not within the standard value range,
adjust by changing the push rod length by turning the
adjustable end of the push rod.
Caution
Improper clearance may cause excessive brake drag.
5-58 BRAKES - Master Cylinder
IISASSEMBLY AND REASSEMBLY
r------1
NOMA-
1 14 14UO125
I ii
Brake master cylinder kit
:.5i340,b;m
- . .
.3.0 Nm
ft.lbs.
; .5F3h0,bfm
- . - +-
10
MAO575
Disassembly steps 11. Gasket

1. Reservoir cap assembly aLI) 12. Piston stopper ring
2. Diaphragm +e ~~ 13. Primary piston assembly
3. Reservoir cap +e W 14. Secondary piston assembly
4. Filter ~~ 15. Master cylinder body
;: ;3r&e fluid level sensor
FrEeverse the disassembly procedures to reassemble.
7. Reservoir (2) 4e : Refer to “Service Points of Disassembly”
I)+ 8. Nipple (3) l + : Refer to “Service Points of Reassembly”
9. Reservoir seal I;! m : Non-reusabje p a r t s
4+ 10. Piston stopper bolt * : Vehicles with ABS
BRAKES - Master Cbhder 5-59
SERVICE POINTS OF DISASSEMBLY ’ NOSH&
10. DISASSEMBLY OF PISTON STOPPER BOLT
Remove the piston stopper bolt, while depressing the
piston.
12. DISASSEMBLY OF PISTON STOPPER RING

Remove the piston stopper ring, while depressing the
piston.
13. DISASSEMBLY OF PRIMARY PISTON ASSEMBLY
Caution
Do not disassemble the primary piston assembly.
14. DISASSEMBLY OF SECONDARY PISTON ASSEMBLY
NOTE
If it is hard to remove the secondary piston from the
cylinder, gradually apply compressed air from the outlet
port on the secondary end of the master cylinder.
Caution
Do not disassemble the secondary piston assembly.
INSPECTION NOWDAC
l Check the inner surface of master cylinder body for rust or

pitting.
l Check the primary and secondary pistons for rust, scoring,
wear, damage or wear.
l Check the diaphragm for cracks and wear.
SERVICE POINTS OF REASSEMBLY NOWCAI
15. APPLICATION OF FLUID TO MASTER CYLINDER

BODY / 14. SECONDARY PISTON ASSEMBLY/ 13. PRI-
MARY PISTON ASSEMBLY
Apply the specified brake fluid sufficiently to the inner
surface of the master cylinder body and to the entire
surface of the secondary and primary pistons.
Conforming to DOT3
I 14LO211
8. INSTALLATION OF NIPPLES
Be sure that the primary side nipple and secondary side
nipple are not mistaken one for the other when installed.
14AO237
5-60 BRAKES - Brake Booster
BRAKE BOOSTER
I Pre-removal Operation
l Drainino of Brake Fluid I
MA0392
Removal steps
1. Relay box (for air conditioner)
2. Solenoid valve assembly
3. Brake fluid level sensor connector
4. Brake tube
5. Master cylinder, hose, reservoir assembly
+I) e+ 6. Vacuum hoses with check valve
+a 7. Fitting
8. Cotter pin
I)4 9. Washer
I)4 10. Clevis pin NOTE
11. Fuel return tube installation bolt (1) Reverse the removal procedures to reinstall.
12. Brake tube installation bolt (2) ** : Refer to “Service Points of Removal”.
13. Brake booster (3) l * : Refer to “Service Points of Installation”.
14. Sealer (4) m : Non-reusable parts
BRAKES - Brake Booster 5-61
SERVICE POINTS OF REMOVAL Now9Al
Vacuum hose 6. REMOVAL OF VACUUM HOSE WITH CHECK VALVE
NOTE
Since the check valve is fit to the vacuum hose, replace the
check valve as an assembly unit together with the vacuum
hose if the check valve is defective.
MAO394
SERVICE POINTS OF INSTALLATION NOWDAV
10. APPLICATION OF GREASE TO CLEVIS PIN/g. WASHER

After applying the specified grease to the clevis pin and
washer, insert the clevis pin and bend the cotter pin tightly.
14uoo50
7. APPLICATION OF SEALANT TO FITTING

When installing the vacuum hose fitting, apply semi-drying
sealant to its threaded portion.
14Y626
Vacuum hose
6. INSTALLATION OF VACUUM HOSE WITH CHECK
VALVE
(1) Attach the vacuum hose so that it may be inserted to a
dimension illustrated.
Caution
Prevent interference between the check valve and
brake booster.
(2) The vacuum hose at the engine should be securely
connected until it contacts the hexagonal edge of the
mm (in.) 14A0395 fitting, and then should be secured by the hose clip.
5-62 BRAKES - Brake Line
BRAKE LINE
REMOVAL AND INSTALLATION NOSKA-
r/ehicles without ABS Pre-removal Operation

eDraining of Brake Fluid >/
Flared brake line nuts

13-17 Nm
6 9-12 ft.lbs. I
/
14FO38
25-35 N m
/ 18-25 ftlbs.
17-26 Nm
12-19 ft.lb!5. 25-35 Nm
18-25 ftlbs.
12-19 ft.lbs.
1. Front brake hose

2. Strut brake tube
3. Front brake tube (R.H.)
4. Front brake tube (L.H.)
5. Brake tube (A)
6. Brake tube (9)
11. Main brake tube (R.H.)
12. Main brake tube (L.H.)
13. Proportioning valve
14. Rear brake hose
15. Rear axle brake tube
MAO583
16. Bracket
BRAKES - Brake Line 5-63
Vehicles with ABS
*Draining of Brake Fluid
-- Zonnecting part of
17-26 Nm
12-19 ftlbs.
14A057i!
17-26 Nm
12-19 ft.lbs.
4* 1. Front brake hose

2. Strut brake tube
3. Front brake tube (R.H.)
4. Front brake tube (L.H.)
5. Brake tube (A)
6. Brake tube (9)
7. Rear brake tube (R.H.)
8. Rear brake tube (L.H.)
~~ 9. Hydraulic unit 14A0585
10. Main brake tube (R.H.)
11. Main brake tube (L.H.)
2: 12. Proportioning valve
13. Rear brake hose
14. Rear axle brake tube
15. Bracket
5-64 BRAKES - Brake Line
.m L
SERVICE POINTS OF REMOVAL N88K8AMll
Brake r-e
tube 1. REMOVAL OF FRONT BRAKE HOSE/13. REAR BRAKE
HOSE
(1) Holding the lock nut on the brake hose side, loosen the i
flared brake line nut.
(2) Pull off the brake hose clip and remove the brake hose
from the bracket.
12. REMOVAL OF PROPORTIONING VALVE
Do not disassemble the proportioning valve because its
14w593 Brake hose ,4”ooe~ performance depends on the set load of the spring.
INSPECTION NO5KCAh
l Check the brake tubes for cracks, crimps and corrosion.

l Check the brake hoses for cracks, damage and leakage.
l Check the flared brake line nuts for damage and leakage.
SERVICE POINTS OF INSTALLATION NO5KDAJ
9. CONNECTION OF TUBE TO HYDRAULIC UNIT

Connect the tubes to the hydraulic unit as shown in the
illustration.
1. From the hydraulic unit to the front

brake (L.H.)
2. From the hydraulic unit to the pro-
portioning valve (Rear, R.H.)
3. From the hydraulic unit to the front
brake (R.H.)
4. From.,the hydraulic unit to the pro-
portioning valve (Rear, L.H.)
5. From the master cylinder
(for left front and right rear)
6. From the master cylinder
(for right front and left rear)
BRAKES - Front Disc Brake 5-65
FRONT DISC BRAKE
’ REMOVAL AND INSTALLATION NOSLA--
13-17 Nm 80-100 Nm l Draining of Brake Fluid
9-12 ft.lbs.,
14A0420
Removal steps
W M 1. Connection for the brake hose and the NOTE
brake tube (I) Reverse the removal procedures to reinstall.
l + 2. Front brake assembly (2) +I) : Refer to “Service Points of Removal”.
3. Brake disc (3) l * : Refer to “Service Points of Installation”.
SERVICE POINTS OF REMOVAL N-LEAF
1. DISCONNECTION OF BRAKE HOSE

Holding the nut on the brake hose side. Loosen the flared
brake line nut.
INSPECTION NOSLCAD
INSPECTION OF BRAKE DISC

l Check disc for wear. (Refer to P.5-47, Front Brake Disc
Thickness Check.)
l Check disc for runout. (Refer to P.5-47, Front Brake Disc
Run-out Check.)
l Check disc for damage
5,966 BRAKES - Front Disc Brake
SERVICE POINTS OF INSTALLATION NO5LDAG
2. INSTALLATION OF FRONT BRAKE ASSEMBLY

(1) Measure hub torque with pad removed to measure
brake drag torque after pad installation.
NOTE
14A0400
(2) After installing the caliper support to the knuckle,

expand the piston, and then install the caliper body.
1. INSTALLATION OF BRAKE HOSE

Install brake hose without twisting or kinking.
Check brake drag torque as follows.
(2) Stop engine.
the piston. Check for corrosion or worn piston seal.
1410399
Standard value: 70 N (15 Ibs.) or less
[4 Nm (3 ft.lbs.)J or less
NOSLE-B
.16
64-86
46-62
64-86
46-62 ft.lbs. ;
Brake caliper kit

Caliperassembly disassembly steps
l + 1. Guide pin 3
l + 2. Lock pin
l + 3. Bushing
4. Caliper support (Pad, clip, shim)
e+ 5. Guide pin boot
l 6. Lock pin boot
7. Boot ring
:: 8. Piston boot
l *** 9. Piston
4I) l + 10. Piston seal
Il. Brake hose
l + 12. Caliper body
Pad assembly disassembly steps

l + 1. Guide pin Seal and boots
l + 2. Lock pin Pad repair kit repair kit
l * 3. Bushing
4. Caliper support (Pad, clip, shim)
13. Pad and wear indicator assembly
14. Pad assembly 14 10 6
15. Outer shim
16. Clip 13
13
(1) Reverse the disassembly procedures to reassemble. 14 5

(3) l O : Refer to “Service Points of Reassembly”. 16 16
(4) m : Non-reusable parts 14AO539 14A054(3
5-68 BRAKES - Front Disc Brake
SERVICE POINTS OF DISASSEMBLY NO5LFAJ
When disassembling the front disc brakes, disassemble both

sides (left and right) as a set.
7. REMOVAL OF BOOT RING
Remove boot ring with flat tip (-) screwdriver.
14KO54 14GOO54
8. REMOVAL OF PISTON BOOT/g. PISTON

Protect caliper body with cloth. Blow compressed air
through brake hose to remove piston boot and piston.
Caution
Blow compressed air gently.
14K057
10. REMOVAL OF PISTON SEAL

(1) Remove piston seal with finger tip.
Caution
Do not use flat tip (-) screwdriver or other tool to
prevent damage to inner cylinder.
(2) Clean piston surface and inner cylinder with trichloro-
ethylene, alcohol or specified brake fluid.
Conforming to DOT3
INSPECTION NOSLGAJ
l Check cylinder for wear, damage or rust.

l Check piston surface for wear, damage or rust.
l Check caliper body guide pin or lock pin for wear.
l Check pad for damage or adhesion of grease, check
backing metal for damage.
PAD WEAR CHECK

Measure thickness at the thinnest and worn area of the pad.
Replace pad assembly when pad thickness is less than the limit
value.
Limit value: 2.0 mm (.08 in.)
14UOO72
SERVICE POINTS OF REASSEMBLY NOSLli@
12. APPLICATION OF BRAKE FLUID TO CALIPER BODY

Apply specified brake fluid to inner cylinder.
Conforming to DOT3
10. INSTALLATION OF PISTON SEAL
Install piston seal in cylinder groove.
Caution
14KO60 Do not wipe special grease on piston seal.
9. INSTALLATION OF PISTON
(1) Apply specified brake fluid to piston. Insert into cylinder
without twisting.
Conforming to DOT3
(2) Fill piston edge with specified grease. Install piston

boots.
Specified grease: Repair kit grease (orange)
Piston boot’
14KO70
I
6. APPLICATION OF GREASE TO LOCK PIN BOOT/5.
GUIDE PIN BOOT/3. BUSHING
Grease parts as illustrated with specified grease.
Grease
I I 14A0541 I
2. INSTALLATION OF LOCK PIN/l. GUIDE PIN

Install the guide pin and lock pin so the identification mark
on the caliper body and head mark on the guide pin and lock
pin are aligned.
5-70 BRAKES -’ Rear Disc Brake
REAR DISC BRAKE

@Draining of Brake Fluid ~1 ,.
<FM/D> l Adjustment of Parking Brake Lever
50-60 Nm 1. 1
9-14 Nm 36-43 ft.lbs.

7-10 ft.lbs. /
7- 10 ft.lbs.
Removal steps
1. Parking brake cable connection
4* 2. Brake hose connection
3. Rear brake assembly
4. Rear brake disc
MAO574
5. Hubcab
+4 76. ME;AFearing n u t
NOTE
8: Rear speed sensor bracket (1) Reverse the removal procedures to reinstall.
<Vehicles with ABS> (2) +* : Refer to “Service Points of Removal”.
9. Rear hub assembly (3) ** : Refer to “Service Points of Installation”.
14. Dust shield (4) m : Non-reusable parts
BRAKES - Rear Disc Brake 59q!l
<AWD>
50-60 Nm
36-43 ft.lbs.
9-14 Nm
55-65 Nm
39-47 klbs.
/
160-220 Nm
116-159 ft.lbs.
14A0222
@Draining of Brake Fluid
1. Parking brake cable connection l supplying Brake Fluid
4* 2. Brake hose connection
3. Rear brake assembly (Refer to P.5-45.)
4. Rear brake disc l Adjustment of Parking Brake Level
+e l + IO. Self locking nut Stroke
r)+ 11. Companion flange P.5-42.)
12. Rear speed sensor
KVehicles with ABS> NOTE
+e l 13. Rear axle shaft (1) Reverse the removal procedures to reinstall.
(2) +e : “Service
(3) I)+ : Refer to “Service Points of Installation”.
5-72 BRAKES - Rear Disc Brake
SERVICE POINTS OF REMOVAL NO5MBAD
Brake tube
2. DISCONNECTION OF BRAKE HOSE
e
Holding the lock nut on the brake hose side, loosen the /
flared brake line nut.
Brake hose
14w593
10. REMOVAL OF SELF LOCKING NUT

Using the special tool, secure and hold the rear axle shaft,
and remove the self locking nut.
13. REMOVAL OF REAR AXLE SHAFT

Using the special tool, remove the rear axle shaft.
INSPECTION NO5MDABa rq.
l Check disc for wear. (Refer to P.5-15, Rear Brake Disc

Thickness Check.)
0 Check disc for runout. (Refer to P.5-16, Rear Brake Disc
Run-out Check.)
l Check disc for damage.
12A0611
SERVICE POINTS OF INSTALLATION NOSMCAF
13. INSTALLATION OF REAR AXLE SHAFT/ 11.

COMPANION FLANGE/IO. SELF LOCKING NUT
(1) Provisionally install the rear axle shaft to the trailing
(2) ;‘,‘%I, the companion flange to the rear axle shaft, and
install the self locking nut.
(3) Then, using the special tool, secure and hold the rear
axle shaft, and tighten the self locking nut.
6. INSTALLATION OF WHEEL BEARING NUT

After tightening the wheel bearing nut, align with the
indentation in the spindle, and then crimp.
BRAKES - Rear Disc Brake 5-73
IISASSEMBLY AND REASSEMBLY

<AWD> 1
c*:O 55 Nm
29-40 ft.lbs.
25-35 N m
18-25 ft.lbs.
<FWD> ;
7-9 Nm
5 - 7 ft.lbs.
I
13-17 Nm
9-12 ftlbs.
22-32 N m
16-23 fi.J,,s. b-
1 Q \\T;
Grease
Brake seal kit
Caliper assembly disassembly steps

1. Connection for brake hose
2. Lock pin 26
N 4. Lock pin sleeve
M 5. Lock pin boot
l 6. Guide pin boot 25
7. Boot ring 26
l + 8. Piston boot 25
+e W+ 9. Piston assembly
** l + 10. Piston seal
l * l + Il. Snap ring 14AO219
12. Spring case
13. Return spring Brake pad kit
14. Stopper plate
15. Stopper
~~ 16. Auto-adjuster spindle
I)+ 17. Connecting link
I)+ 18. O-ring
l + 19. Spindle lever Nm I
l + 20. Lever boot ftlbs. 29 3.
21. Parking brake lever
22. Return spring
23. Bleeder screw
24. Caliper body
Pad assembly disassembly steps
1. Lock pin 2
*I) 3. Support mounting (pad, shim, clip)
25. Outer shim
26. Pad assembly
2 7 . Padclips C NOTE
28. Pad clips B (I) Reverse the disassembly procedures to reassemble.
29. Guide pin (2) l I) : Refer to “Service Points of Disassembly”.
30. Guide pin sleeve (3) H : Refer to “Service Points of Reassembly”.
31. Support mounting (4) 19 : Non-reusable parts
SERVICE POINTS OF DISASSEMBLY NO5NBAE
When disassembling the rear disc brakes, disassemble both

sides (left and right) as a set.
3. REMOVAL OF SUPPORT MOUNTING
With the lock pin removed, pull the support mounting off
from the caliper body.
9. DISASSEMBLY OF PISTON ASSEMBLY
Use the special tool to twist the piston out of the caliper
1410062 body.
10. DISASSEMBLY OF PISTON SEAL

(1) Remove piston seal with finger tip.
Caution
Do not use flat tip (-) screwdriver or other tool to
prevent damage to inner cylinder.
(2) Clean piston surface and inner cylinder with trichloro-
ethylene, alcohol or specified brake fluid.
Conforming to DOT3
11. DISASSEMBLY OF SNAP RING

While using a 19 mm (75 in.) diameter steel pipe to press
the spring case into the caliper body, use the snap ring
pliers to remove the snap ring from the caliper body.
14R0050
INSPECTION N65NCAAa
e Check the connecting link and the spindle for wear or

damage.
l
l Check the spindle lever shaft for rust.
l
l Check the piston for rust.
Check the piston seal for wear or deterioration.
l piston
PAD WEAR CHECK

(1) Measure the thickness of the pad at the thinnest place.
(.08
(2) If the pad assemblies are worn beyond the limit, replace
them.
14UOO72
BRAKES - Rear Disc Brake 5-75
SERVICE POINTS OF REASSEMBLY NiSNDAF
20. APPLICATION OF GREASE TO LEVER BOOT/19.

SllNDLE LEVER/ 18. O-RING/ 17. CONNECTING LINK/
16. AUTO-ADJUSTER SPINDLE
Apply the specified grease to the lever boot, spindle lever,
O-ring, connecting link, auto-adjuster spindle.
- Lever Specified grease: Repair kit grease (Orange)
boot
14RDD52
11. REASSEMBLY OF SNAP RING

While using a 19 mm (.75 in.) diameter steel pipe to press
in the spring case, use the snap ring pliers to attach the
snap ring to the caliper body.
Caution
Attach the snap ring to the caliper body with the
opening facing the bleeder.
10. APPLICATION OF GREASE TO PISTON SEAL

Apply the specified grease to the piston seal and the
cylinder walls and then insert the pi,ston seal into the
cylinder.
Specified grease: Repair kit grease (Orange)
9. REASSEMBLY OF PISTON ASSEMBLY

(1) Push the piston into the caliper with special tool.
NOTE
Align the grooves as illustrated.
a grooves
(2) The pins on the back side of the brake pad must be
placed in the grooves in the position.
0 0
8. APPLICATION OF GREASE TO PISTON BOOT

Apply the specified grease to the piston boot mounting
grooves in the caliper body and in the piston, and then
install the piston boot.
Specified grease: Repair kit grease (Orange)
hide pin end Lock pin end 6. APPLICATION OF GREASE TO GUIDE PIN BOOT/
Caliper support 5. LOCK PIN BOOT/4. LOCK PIN SLEEVE
Apply the specified grease to the following points:
(1) Guide pin boot inner surface (lip)
(2) Lock pin boot inner surface (lip)
(3) Lock pin sleeve (not on threads)
After assembling the rear disc brake assembly, install to the
body, and then make the adjustment of the parking brake
lever as described below.
(1) Free the parking brake cable.
(2) With the engine running, firmly depress the brake pedal
five or six times.
(3) Check whether or not the stroke of the parking brake
lever is within the standard value.
Standard value: 5-7 notches
(4) If there is a deviation from the standard value, adjust
the stroke of the parking brake lever.
(Refer to P.5-42.)
BRAKES - Hydraulic Unit <Vehicles with ABS>
HYDRAULIC UNIT <VEHICLES WITH ABS>

--. REMOVAL AND INSTALLATION
Removal steps
6
1
(Refer to GROUP II-Intercooler.)
I)+ 1. Brake tube connection
2. Relay box cover
3. Hydraulic unit harness connection Post-installation Operation
~~ l 4. Hydraulic unit @Supplying Brake Fluid
aBleeding (Refer to P.5-45.)
5. Hydraulic unit bracket assembly @Installation of Air Pipe B
6. Bracket (Refer to GROUP II-Intercooler.)
7. Valve relay
8. Motor relay NOTE
9. Connector bolt (1) Reverse the removal procedures to reinstall.
10. Connector (2) +e : Refer to “Service Points of Removal”.
11. Gasket (3) e+ : Refer to “Service Points of Installation”.
5-78 BRAKES - Hydraulic Unit <Vehicles with ABS>
SERVICE POINTS OF REMOVAL
4. REMOVAL OF HYDRAULIC UNIT b-3
Remove the installation nuts, and then take out the __
hydraulic unit upward.
Caution
1. The hydraulic unit is heavy, and so care should be
taken when removing it.
2. The hydraulic unit is not to be disassembled; its
nuts and bolts should absolutely not be loosened.
3. The hydraulic unit must not be dropped or other-
wise subjected to impact shocks.
4. The hydraulic unit must not be turned upside down
or laid on its side.
Aotor relay INSPECTION

Check whether there is continuity between terminals when
there is no current flow at each relay and when there is current
flow.
JlOTOR RELAY
Between
30-60 52
When no terminals @-@I
current flows Between No continuity
16R0670 terminals @I-@ (WQ)
When current
flows between Between Continuity
terminal terminals @--@ (approx. 0 8)
@-@
16Rl773
BRAKES - Hydraulic Unit <Vehicles with ABS> 5-79
Jalve r e l a y /ALVE RELAY
Between
60-120 &2
terminals @-@
When no Between Continuity

current flows terminals @I--@ (approx. 0 Q)
Between No continuity
terminals @J-Q (wQ2)
When current Between No continuity

16R0670
flows between terminals @-@I (WQ)
terminal
87a Between Continuity
@-@ terminals @--@ (approx. 0 S22)
16Rl772

4. INSTALLATION OF HYDRAULIC UNIT
Fasten the ground wire to hydraulic unit bracket assembly.
1. CONNECTION OF BRAKE TUBE

When connecting the tubes to the hydraulic unit, be sure
they are connected correctly.
(Refer to P.5-64.)
5-80 BRAKES - Wheel Speed Sensor <Vehicles with ABS>
WHEEL SPEED SENSOR <VEHICLES WITH ABS> N06dYAG
REMOVAL AND INSTALLATION 4.

<FM/D>
9-14 Nm
7-10 ft.lbs.
-/ ?’
9 - 1 4 Nm
7- 10 ft.lbs. / 7-11 Nm
5
14A0584
Front speed sensor removal steps

4* I. Front toothed rotor
2. Clip
3. Connection for front speed sensor
+e l + 4. Front speed sensor
l + 5. Front speed sensor bracket
Rear speed sensor removal steps

** 6. Rear toothed rotor
7. Clip
8. Cable band NOTE
9. Connection for rear speed sensor (1) Reverse the removal procedures to reinstall.
+e I)* 10. Rear speed sensor (2) 4* : Refer to “Service Points of Removal”.
l + 11. Rear speed sensor bracket (3) l * : Refer to “Service Points of Installation”.
BRAKES - Wheel Speed Sensor <Vehicles with ABS> 5-81;
<AWD>
I Post-installation Operation
@Installation of the Snlash Shield
1 (Refer to GROUP 23-Fender.)
I
1
7 - 1 1 Nm
7-10 ft.lbs.
14A0582
Front speed sensor removal steps

4* 1. Front toothed rotor
2. Clip
3. Front speed sensor connection
4I) WI 4. Front speed sensor
l 5. Front speed sensor bracket
Rear speed sensor removal steps

6. Rear toothed rotor
(Refer to GROUP 27-Rear Axle Hub.)
7. Clip NOTE
8. Cable band (1) Reverse the removal procedures to reinstall.
9. Rear speed sensor connection (2) +e : Refer to “Service Points of Removal”.
4I) W 10. Rear speed sensor (3) I)+ : Refer to “Service Points of Installation”.
12. O-ring (4) m : Non-reusable parts
1. REMOVAL OF THE FRONT TOOTHED ROTOR e
Refer to GROUP Z-Hub and Knuckle.
Caution
Care must be taken not to scratch or scar the rotor’s
toothed surface, and not to drop it.
If the rotor’s toothed surface is chipped or the rotor is
deformed, it might not be able to accurately sense the
wheel rotation speed and the system as a result might
__ r- 14A& not perform normally.
4. REMOVAL OF FRONT SPEED SENSOR

Remove the mounting bolts which hold the speed sensor
bracket to the knuckle, and then remove the speed sensor.
Caution
the speed sensor and the toothed edge of the rotor so
6. REMOVAL OF REAR TOOTHED ROTOR ’

For FWD vehicles refer to GROUP 17-Rear Axle Hub, for
AWD vehicles refer to GROUP 3-Axle Shaft.
Caution r*
Care must be taken not to scratch or scar the rotor’s
toothed surface, and not to drop it.
If the rotor’s toothed surface is chipped or the rotor is
deformed, it might not be able to accurately sense the
wheel rotation speed and the system as a result might
I
not perform normally.
I 14A0215
10. REMOVAL OF REAR SPEED SENSOR

Remove the speed sensor bracket and rear axle spindle
installation nut, and then remove the speed sensor.
Caution
the speed sensor and the toothed edge of the rotor SO
+ont weed sensor Rear meed sensor INSPECTION

SPEED SENSOR CHECK
(1) Check whether any metallic foreign material has adhered to
the pole piece at the speed sensor tip, and, is so, remove it.
Also check whether the pole piece is damaged, and, if so, h
replace it with a new one. ‘J
Pole piece Pole piece

14R0144
BRAKES - Wheel Speed Sensor <Vehicles with ABS> 5-83
<MID> <AWD> NOTE
The pole piece can become magnetized because of the
Front
magnet built into the speed sensor, with the result that
metallic foreign material easily adheres to it. Moreover, the
pole piece may not be able to function to correctly sense
the wheel rotation speed if it is damaged.
Rear
(2) Measure the resistance between the speed sensor termi-
nals.
Standard value: 0.8-1.2 kQ
14AO048 If. the internal resistance of the speed sensor is not within
the standard value, replace it with a new speed sensor.
(3) Check the speed sensor cable for breakage, damage or
disconnection; replace with a new one if a problem is
found.
NOTE
When checking for cable damage, remove the cable clamp
part from the body and then bend and pull the cable near
the clamp to check whether or not temporary disconnec-
tion occurs.
TOOTHED ROTOR CHECK

Check whether rotor teeth are broken or deformed, and, if so,
replace the rotor.
14R0146

11. INSTALLATION OF REAR SPEED SENSOR BRACKET
Qfs
0 Assemble the speed sensor and the speed sensor bracket.
R /or L
0
NOTE
The shape is different for the left and right speed sensor
0 (-J
brackets. Each bracket has an identification symbol, so be
sure to note these symbols and install correctly.
R: Indicates that the bracket is for the right wheel.
L: Indicates that the bracket is for the left wheel.
14AOO47
Left side view 10. INSTALLATION OF REAR SPEED SENSOR <MID>
Right side
(1) Teimn;rarily install the speed sensor to the rear axle
Caution
the speed sensor and the toothed edge of the rotor
so as not to damage them by striking against metal
objects.
(2) Note the following points when connecting the speed
14AOO4:
sensor cable, and secure the cable by the clip.
@I Secure the clip so that the white-painted part
Left side view (shaded in the illustration) of the speed sensor cable
Left side is not twisted.
@ Be sure that there is space (where shown in the
illustration) so that the trailing arm and speed
sensor cable do not contact, and then secure by the
clip.
Caution
Because there is the possibility of damage to the
cable during driving if the speed sensor cable and
the trailing arm come into contact, or if the speed
14A004.f sensor cable is twisted, care must be taken regard-
ing this point.
(3) Insert a feeler gauge into the space between the speed
sensor’s pole piece and the rotor’s toothed surface, and
then tighten the speed sensors at the position where
the clearance is the standard value.
NOTE
Check to be sure that there is no contact of the speed
sensor’s pole piece and the rotor’s toothed surface
when the rear hub assembly is slowly rotated one time.
If there is contact, it is probable that the rotor or the rear
hub is installed incorrectly, recheck installation.
10. INSTALLATION OF REAR SPEED SENSOR <AWD>
Install the rear speed sensors as shown in the illustration.
Cross-section A-A
Parking cable
Rear spe/ed
sensor 12A0075
Cross-section B-B Cross-section C-C
Rear speed
sensor
Crossmember
VA0074 12AOO76 12AOO77

BRAKES - Wheel Speed Sensor <Vehicles with ABS> 545
5. INSTALLATION OF FRONT SPEED SENSOR BRACKET

Assemble the speed sensor and the speed sensor bracket.
NOTE
(1) The shape is different for the left and right speed
sensor brackets. Each bracket has an identification
symbol, so be sure to note these symbols ahd. install
correctly.
FR: Indicates that the bracket is for the front speed
sensor.
R: Indicates that the bracket is for the right wheel.
14LOl89
L: Indicates that the bracket is for the left wheel.
(2) Check to be sure, when installing the speed sensor to
the bracket, that the letters “FR” are visible.
4. INSTALLATION OF FRONT SPEED SENSOR
(1) Temporarily install the speed sensor to the knuckle.
Caution
the speed sensor and the toothed edge of the rotor
so as not to damage them by striking against other
parts.
(2) Note the following points when connecting the speed

sensor cable, and secure the cable by the clip.
@ Secure the cable by the clip so that the white-
painted parts of the blackened parts (in the illustra-
tion) of the speed sensor cable are within the range
of the angles indicated by cross-section A-A and
cross-section B-B in the illustration.
@ Check to be sure that the white-painted part
(shaded in the illustration) of the speed sensor cable
is not twisted.
Caution
Because there is the possibility of damage to the
Cross-section A-A Cross-section B-B cable during driving if the speed sensor cable is
twisted, care must be taken regarding this
point.
12R015i
(3) Insert a feeler gauge into the space between the speed
sensor’s pole piece and the rotor’s toothed surface, and
then tighten the speed sensor at the position where the
clearance is the standard value all around.
NOTE
If the clearance between the speed sensor’s pole piece
and the rotor’s toothed surface is not within the
standard value range, it is probable that the rotor is
incorrectly installed, recheck installation.
BRAKES - G-sensor <AWD-ABS>
G-SENSOR <AWD-ABS> N&OVA8
14AO595
G-sensor removal steps

1. Wiring harness connector
NOTE 2. G-sensor
Reverse the removal procedures to reinstall. 3. G-sensor bracket
INSPECTION
(1) Place the sensor on a level surface, then check that there is
conductance between the terminals.
14AO194
(2) Slowly inclining the G-sensor in the direction of forward

vehicle travel, check that there is no conductance above a
sensor angle of 30 degrees.
14A0195
BRAKES - G-sensor <AWD-ABS>/Electronic Control Unit <Vehicles with ABS>
5-87
I (3) Slowly inclining the G-sensor in the direction of reverse
vehicle travel, check that there is no conductance above a
sensor angle of 30 degrees.
14AO198
NOSOZAE
ELECTRONIC CONTROL UNIT <VEHICLES WITH ABS>
@Removal of the Quarter Trim (R.H.)
(Refer to GROUP 23-Trim.)
I
4
*Installation of the Quarter Trim I
1 (RIt?.) (Refer to GROUP 23-Trim.)1
14AO584
Removal steps
4* 1. Electronic control unit connection
l + 2. Electronic control unit
3. Bracket
NOTE
(3) l + : Refer to “Service Points of Installation”.

1. DISCONNECTION OF ELECTRONIC CONTROL UNIT
Unlock the connector and take the connector out.
BRAKES - Elect ronic Control Unit <Vehicles with ABS>/Parking Brakes

2. INSTALLATION OF ELECTRONIC CONTROL UNIT %
When installing the electronic control unit to the bracket,
fasten the connector’s ground wire to the bracket.
After connecting the connector to the electronic control
unit, secure the connector by the holding spring.
PARKING BRAKES
NOSYA-
*i aParking Brake Lever Stroke Adjust-
(Refer to GROUP 23-Floor Console.)
<FWD>
Parking brake lever removal steps I I

1. Adjusting nut 6 7
2. Parking brake stay
l + 3. Bushing
4. Parking brake switch
W 5. Parking brake lever h
Parking brake cable removal steps 4
1. Adjusting nut l?TFeverse the removal procedures to reinstall.
6. Parking clip (2) +e : Refer to “Service Points of Removal”.
7. Retainer spring (3) I)4 : Refer to “Service Points of Installation”.
l * 8. Parking brake cable
BRAKES - Parking Brakes 5-89
<AWD>
14A0527
aRemoval of Floor Console (Refer to
GROUP 23-Floor Console)
Removal steps of the parking brake lever

1. Adjusting nut
2. Parking brake stay @Parking Brake Lever Stroke Adjustment
W 3. Bushing
4. Parking brake switch l installation of Floor Console (Refer to
l + 5. Parking brake lever
Removal steps of the parking brake cable
1. Adjusting nut NOTE
6. Parking clip (1) Reverse the removal procedures to reinstall.
:: 7. Retainer spring (2) 4e : Refer to “Service Points of Removal”.
l + 8. Parking brake cable (3) l 4 : Refer to “Service Points of Installation”.
SERVICE POINTS OF REMOVAL N05YBAJ
6. REMOVAL OF PARKING CLIP/7. RETAINER SPRING

Remove the parking clip and retainer spring and disconnect
the parking brake cable from the rear brake as&mbly.
INSPECTION NO5YCAI
l Check the parking brake lever ratchet for wear.

l Check the parking brake lever for damage and operation.
5-90 BRAKES - Parking Brakes
SERVICE POINTS OF INSTALLATION NO!iYDAKa
8. INSTALLATION OF PARKING BRAKE CABLE

Identification mark Check the parking brake cables for an identification mark
and install as appropriate on the left and right sides.
Item FWD AWD

I
Left side None Yellow
Identification
mark Right side White Orange
5. APPLICATION OF GREASE TO PARKING BRAKE LEVER

Apply a coating of the specified grease to each sliding parts
of the ratchet plate or the ratchet pawl.
Cross-section A-A Cross-section B-B
14A0411 14AO442
&=4-- 1 3. APPLICATION OF GREASE TO BUSHING

Apply a coating of the specified grease to the inner surface
of the bushing.
Grease: MOPAR Multi-mileage 1 lhifinnt ._I. ..v-.--
Part No. 2525035 or eq uivalent
1 14A0414
6-I
CLUTCH
CONTENTS
CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SPECIFICATIONS . . . . . . . . . . . . . . . . . . ..m........................ 2

CLUTCH COVER AND DISC .......................... 16
Lubricants ...................................................... 3
CLUTCH MASTER CYLINDER ........................ 11 Service Specifications ................................... 2
Torque Specifications ................................... 3
CLUTCH PEDAL .............................................. 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . ..*............ 4
CLUTCH RELEASE CYLINDER . . . . . . . ..a............. 13
Clutch chatters
SERVICE ADJUSTMENT PROCEDURES . . . . . . . 5 Clutch noise
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clutch pedal feels “heavy”
Clutch Pedal Inspection and Adjustment . . . . 5 Clutch slips
Gear shift malfunction
SPECIAL TOOL ,.,#mmm,.*......B......................*........ 3
CAUTION
When servicing clutch assemblies or com-
ponents for vehicles with 1.8L engine, do
NOT create dust by sanding or by cleaning
clutch parts with a dry brush or with
compressed air. (A water dampened cloth
should be used). The clutch disc contains
“Asbestos Fibers” which can become air-
borne if dust is created during service
operations. Breathing dust containing
“Asbestos Fibers” may cause serious
bodily harm.
6-2 CLUTCH - SDecifications
SPECIFICATIONS
Items 1.8L Engine 2.0L DOHC Engine 2.0L DOHC Engine

<Non Turbo> <Turbo>
Clutch operating method Hydraulic type Hydraulic type Hydraulic type
Clutch disc*
Type Single dry disc type Single dry disc type Single dry disc type
Facing diameter
O.D. x I.D. mm (in.) 200 x 130 2 1 5 x 140 2 2 5 x 150
(7.9 x 5.1) (8.5 x 5.5) (8.9 x 5.9)
Clutch cover assembly
Type Diaphragm spring strap Diaphragm spring strap Diaphragm spring strap
drive type drive type drive type
Clutch release cylinder
I.D. mm (in.) 20.64 (13/16) 20.64 (13/6) 19.05 (3h)
Clutch master cylinder

I.D. mm (in.) 15.87 (%) 15.87 (%) 15.87 (543)
NOTE
*: Non-asbestos discs on vehicles with 2.0L DOHC Engine.
SERVICE SPECIFICATIONS NO6lX- .H,
L-
Standard value
Clutch pedal height mm (in.) 176.0-I 81 .O (6.93-7.13)
Clutch pedal clevis pin play mm (in.) l-3 (.04-.12)
Clutch pedal free play mm (in.) 6 - 1 3 (.24-.51)
Distance between the clutch pedal and the firewall 55 (2.2) or more
when the clutch is disengaged mm (in.)
Limit
Facing rivet sink mm (in.) 0.3 (012)
Diaphragm spring end height difference mm (in.) 0.5 (.02)
CLUTCH - Specifications/Special Tool 6-3
TORQUE SPECIFICATIONS NMCC-
Items Nm ftlbs.
Clutch pedal to clutch pedal support bracket 20-25 14-18
Clutch pedal support bracket 8-12 6-9
Clutch pedal support bracket to firewall 10-15 7-l 1
Stop light switch 10-15 7-11
Brake booster installation nut 11-17 8-12
Master cylinder to firewall 10-15 7-11
Pedal rod to clutch pedal support bracket 17-26 12-19
Clutch pedal bracket 8-l 2 6-9
Pedal rod to clutch pedal bracket 17-26 12-19
Clutch tube flare nut 13-17 9-12
Air cleaner bracket 8-12 6-9
Clutch tube clamp to body 8-l 2 6-9
Reservoir band 5-7 4-5
Clutch release cylinder 15-22 11-16
Clutch release cylinder to union bolt 25 18
Bleeder plug 9-13 7-9
Fulcrum 35-42 25-30
Clutch cover assembly 15-22 11-16
- LUBRICANTS NOSCD-
Items Specified lubricants
Contact surface of release bearing and fulcrum of clutch MOPAR Multi-mileage Lubricant
release fork Part No.2525035 or equivalent
Inner surface of clutch release bearing
Inner surface of clutch disc spline
Contact portion of release fork to release cylinder push rod
Bushing, clevis pin, washer and bushing
Inner surface of clutch release cylinder and outer MOPAR Brake Fluid/Conforming to DOT3
circumference of piston and cup
Inner surface of clutch master cylinder and outer
circumference of piston assembly
SPECIAL TOOL
MD9981 26 Clutch disc center Clutch disc center hole alignment
guide
\ \
6-4 CLUTCH - Troubleshooting
TROUBLESHOOTING NO6hi.J
Clutch slips Insufficient clutch pedal play Adjust
Excessive wear of clutch disc facing Replace
Hardening of clutch disc facing, or adhesion of oil Replace
Clutch release fork catching Repair or replace parts
Weak or damaged diaphragm spring Replace
Clogging of hydraulic system Repair or replace parts
Gear shift malfunction Excessive clutch pedal play Adjust
Distorted clutch disc, excessive oscillation Replace
Clutch cover assembly worn Replace
Clutch disc spline worn or corroded Replace
Clutch disc facing peeling Replace
Clutch release bearing worn Replace
Damaged pressure plate or flywheel Replace
Leakage, air introduction or clogging of hydraulic system Repair or replace parts
Clutch noise Insufficient clutch pedal play Adjust
Improper installation of clutch cover assembly Repair or replace parts
Excessive wear of clutch disc facing Replace
Clutch release bearing worn Replace
Weak or damaged torsion spring Replace
Damaged pilot bushing Replace
Insufficient lubrication of bearing sleeve sliding surface Repair
Clutch pedal feels “heavy” Insufficient lubrication of clutch pedal Repair
Insufficient lubrication of clutch disc spline Repair
Insufficient lubrication of bearing sleeve sliding surface Repair
Clutch chatters Worn or damaged clutch disc facing Replace
Oil adhered to clutch disc facing Replace
Uneven height of diaphragm spring Repair or replace parts
Weak or damaged torsion spring Replace
Damaged pressure plate or flywheel Replace
Loose or damaged mounting Replace or tighten

mounting
CLUTCH - Service Adjustment Procedures 6-5
Clutch pedal height Clutch pedal clevis SERVICE ADJUSTMENT PROCEDURES
pin play
CLUTCH PEDAL INSPECTION AND ADJUSTMY’,
b
1. Measure the clutch pedal height (from the face of the pedal
pad to the firewall) and the clutch pedal clevis pin play
(measured at the face of the pedal pad.)
Standard value (A): 176.0-181.0 mm (6.93-7.13 in.)
A Standard value (B): l-3 mm (.04-.12 in.)
08YO43
Vehicles without Vehicles with 2. If either the clutch pedal height or the clutch pedal clevis
auto-cruise control auto-cruise control pin play are not within the standard value range, adjust as
system follows :
(1) For vehicles without auto-cruise control system, turn
and adjust the bolt so that the pedal height is the
standard value, and then secure by tightening the lock
nut.
Vehicles with auto-cruise control system, disconnect
the clutch switch connector and turn the switch for
standard clutch pedal height. Then lock with the lock
nut.
NOTE
When the pedal height is lower than the standard value,
loosen the bolt or clutch switch, and then turn the push
rod to make the adjustment. After making the adjust-
ment, tighten the bolt or clutch switch to reach the
pedal stopper, and then lock with the lock nut.
(2) Turn the push rod to adjust the clutch pedal clevis pin
play to agree with the standard value and then secure
the push rod with the lock nut.
08A0025
Caution
When adjusting the pedal height or the clutch pedal
clevis pin play, be careful not to push the push rod
toward the master cylinder.
3. Check to be sure that the interlock switch is as shown in
the illustration when the clutch pedal is depressed its full
stroke [151 mm (6.0 in.)]. If necessary, loosen the lock nut
and adjust.
IClutch pedal free pIa\

4. After completing the adjustments, confirm that the clutch
Distance between the
clutch pedal and the pedal free play (measured at the face of the pedal pad)
firewall when the and the distance between the clutch pedal (the face of the
clutch is disengaged pedal pad) and the firewall when the clutch is disengaged
are within the standard value ranges.
Standard value (C): 6-13 mm (.24-.51 in.)
Standard value (D): 55 mm (2.2 in.) or more
08YO43
6-6 CLUTCH - Service Adjustment Procedures
5. If the clutch pedal free play and the distance between the
clutch pedal and the firewall when the clutch is disengaged
do not agree with the standard values, it is probably the A
result of either air in the hydraulic system or a faulty master 2
cylinder or clutch. Bleed the air, or disassemble and inspect
the master cylinder or clutch.
BLEEDING
Whenever the clutch tube, the clutch hose, and/or the clutch
master cylinder have been removed, or if the clutch pedal is
spongy, bleed the system.
Caution
Use the specified fluid. Avoid using a mixture of the
specified fluid and other fluid.
Specified fluid: MOPAR Brake Fluid/Conforming to DOT3
CLUTCH - Clutch Pedal 6-7
CLUTCH PEDAL
-. REMOVAL AND INSTALLATION NOSPA-

*Removal of the Lap Cooler Duct, l installation of the Relay Box (Indoor)
Shower Duct (L.H.) and Knee Pro- l installation of the Steering Column
tector (Refer to GROUP 23%lnstru- Assembly (Refer to GROUP 19-
ment Panel.) Steering Wheel and Shaft.)
*Removal of the Steering Column l installation of the Lap Cooler Duct,
Assembly (Refer to GROUP 19- Shower Duct (L.H.) and Knee Pro-
Steering Wheel and Shaft.) tector (Refer to GROUP 23 Instru-
*Removal of the Relay Box (Indoor) ment Panel.)
l Adjustment of the Brake Pedal (Re-
fer to GROUP 5-Service Adjust-
ment Procedures.)
aAdjustment of the Clutch Pedal (Re-
fer to P.6-5.)
17-26 Nm
12-19 ft.lbs.
!
<Non-Turbo>
11-17 Nm
8-12 ft.lbs. :k -16
’\ tl(i/:/
l/Y F
IO-15 Nm 20-25 Nm
v .1-m.---
I- I I KIDS.
14-f8 ft.lbs.
<Turbo>
Removal steps
I, Clutch pedal return spring <Non-Turbo>
2. Brake pedal return spring
3. Interlock switch
4. Clutch switch <Vehicles with auto’-cruise
control system> 17. Lever
5. Bolt <Vehicles without auto-cruise control l + 18. Clutch pedal bushing
system> ~~ 19. Clutch pedal bushing
6. Stop light switch 20. Pedal rod
7. Clip e+ 21. Brake pedal bushings
l + 8. Bushing 22. Clutch pedal
9. Turn over spring 23. Brake pedal
.“- e+ IO. Bushing 24. Pedal pad
11. Cotter pin
l + 12. Washer NOTE
l + 13. Clevis pin (2) l + : Refer to “Service Points of
14. Pedal support bracket assembly (3) m : Non-reusable parts
15. Clutch pedal mounting nut
16. Clutch pedal bracket
6-8 CLUTCH - Clutch Pedal
INSPECTION NWFCAG
l Check the pedal shaft and bushing for wear. A

l Check the clutch pedal for bend or torsion.
l Check the return spring for damage or deterioration. -’
l Check the pedal pad for damage or wear.
. INTERLOCK SWITCH INSPECTION

Ohmmeter (1) Disconnect the connector.
(2) Check to be sure that there is continuity between
connector terminals 1 and 2 when the clutch pedal is
depressed fully.
SERVEICE POINTS OF INSTALLATION NOWDAU
21./19./18. APPLICATION OF GREASE TO BUSHING

Apply multipurpose grease to bushings. +%
Grease: MOPAR Multi-Mileage Lubricant
OBAOO40
13. APPLICATION OF GREASE TO CLEVIS PIN/12.

Washer
Apply multiporpose grease to the clevis pin and washer.
OLIA0039
10./8. BUSH INSTALLATION <Turbo>

Apply multiporpose grease to the inside of the bushing.
CLUTCH - Clutch Control 6-9
CLUTCH CONTROL
NOSJA-
--., REMOVAL AND INSTALLATION
l Removal of the Air Cleaner (Refer

l Draining of the Clutch Fluid
to Post-installation Operation
*Supplying of the Clutch Fluid
@Bleeding of the Clutch Line (Refer tC
P.6-6.)
l Adjustment of the Clutch Pedal (Re
fer to P.6-5.)
l installation of the Air Cleaner (Refel
to GROUP 11 - Air Cleaner.)
IO-15 Nm
8-12 Nm 7 - 1 1 ft.lbs.
6 - 9 ftlbs.
13-17 Nm
g-12 ft.lbs.
<Non-Turbo>
13-17 Nm
g- 12 ft.ibs.
6 - 9 ft.lbs.
08A0081
13-17 Nm
9- 12 ft.lbs. Removal steps
1. Cotter pin
l + 2. Washer
l 4 3. Clevis pin
l + 4. Clutch tube
~~ 5. Clutch tube
4* 6. Hose clips
+e I)+ 7. Clutch hose
8. Air cleaner bracket
9. Clutch master cylinder
10. Sealer
NOTE
(2) +e : Refer to “Service Points of Removal”.
I;\ m : Non-reusable, parts
* : <Vehicles with ABS>
640 CLUTCH - Clutch Control
SERVICE POINTS OF REMOVAL Na9JMD

6. DISCONNECTION OF HOSE CLIPSI7. CLUTCH HOSE
To disconnect clutch hose from the clutch tube, proceed
as follows:
(1) Secure the nut on the clutch hose and loosen the flare
nut on the clutch tube.
(2) Remove the clip from the clutch hose to remove clutch
3
~~~ --Clutch tube hose from bracket.
T I) /Hose clip
%5
Clutch hose
INSPECTION NO9JCAC
l Check the clutch hose or tube for cracks or clogging.
SERVICE POINTS OF INSTALLATION NO6JDAJ
7. INSTALLATION OF CLUTCH HOSE/S. CLUTCH TUBE/4.

CLUTCH TUBE
Temporarily tighten the flare nut by hand, and then tighten
it to the specified torque, being careful that the clutch
hose does not become twisted.
Secure side
08W507
3. APPLICATION OF GREASE TO CLEVIS PIN/2. WASHER

Apply multipurpose grease to the clevis pin and washer.
Grease
09AOO39
-
CLUTCH - Clutch Master Cylinder 6-l 1
CLUTCH MASTER CYLINDER
-. DISASSEMBLY AND REASSEMBLY NOGNA-
<Type A>
<Type B>
@Installation of the Clutch Master

Cylinder (Refer to P.6-9.)
Nm
ftlbs.
Disassembly steps
1. Piston stop ring
l + 2. Push rod
NOTE
3. Boot (I) Reverse the disassembly procedures to reassemble.
+e W 4. Piston assembly (2) +e : Refer Points of
5. Reservoir cap (3) I)+ : Refer to “Service Points of Reassembly’.
l + 6. Reservoir band (4) <TYPE A>: Vehicles with auto-cruise control system
7. Reservoir <TYPE B> : Vehicles without auto-cruise control sys-
8. Master cylinder body tem
NO6NBAC
4. REMOVAL OF PISTON ASSEMBLY

Caution
1. Do not damage the master cylinder body and piston
assembly.
2. Do not disassemble piston assembly.
\\ 08AOOi4
INSPECTION NO9NCAC
l Check the inside cylinder body for rust or scars.

l Check the piston cup for wear or deformation.
l Check the piston for rust or scars.
l Check the clutch tube connection part for clogging.
6-12 CLUTCH - Clutch Master Cylinder
SERVICE POINTS OF REASSEMBLY NaaNciAN
6. INSTALLATION OF RESERVOIR BAND
Tighten the resetver band at the illustrated position.
Resew&r band k
oaA0058
4. APPLICATION OF CLUTCH FLUID TO PISTON ASSEM-

BLY
Apply specified clutch fluid to the inner surface of the
cylinder and to the entire periphery of the piston assembly.
Specified fluid: MOPAR Brake Fluid/Conforming to
DOT3
08Y517
2. APPLICATION OF GREASE TO PUSH ROD

Grease Apply a suitable amount of rubber grease on the contact
surfaces between the damper push rod and piston and
between the push rod and boot.
CLUTCH - Clutch Release Cvlinder 6-13
CLUTCH RELEASE CYLINDER
-‘- REMOVAL AND INSTALLATION NaaHA--
@Draining of the Clutch Fluid @Supplying of the Clutch Fluid
@Bleeding of the Clutch Line (Refer to
@Adjustment of the Clutch Pedal (Re-
25
18 EL.
1 13117 Nm 08A0004
IO-12 ftlbs.
Removal steps NOTE

1. Connection of clutch tube (I) Reverse the removal procedures to reinstall.
I)4 2. Clutch release cylinder (2) l * : Refer to “Service Points of Installation”
INSPECTION NOMCAA
l Check the clutch release cylinder for fluid leakage.

l Check the clutch release cylinder boots for damage.
SERVEICE POINTS OF INSTALLATION NO6HDAJ
2. APPLICATION OF GREASE TO CLUTCH RELEASE

CYLINDER
Apply grease
Apply a coating of multipurpose grease at the contact part
\\ :\ of the release cylinder push rod and the release fork.
6-14 CLUTCH - Clutch Release Cylinder
<FWD> /e
, #,,“”
Post-reassembly Operation
l installation of the Clutch Release
Cylinder (Refer to P.6-13.) 7
3
2-3 6CLO37
,---a
#,J,
<AWD> , ‘::.”
/,
,,,d$’ ’
.,:..a
/ : i 01
‘, ., 1
<
3
6
Disassembly steps
I. Valve plate
2. Spring
6CLOOlO
3. Push rod
4. Boots
*+ l 5. Piston and cup
6. Conical spring NOTE
7. Cap (1) Reverse the removal procedures to reassemble.
8. Bleeder plug (2) W : Refer to “Service Points of Disassembly”.
9. Release cylinder (3) I)4 : Refer to “Service Points of Reassembly”.
r I
SERVICE POINTS OF DISASSEMBLY NOOLBAE
5. DISASSEMBLY OF PISTON AND CUP
(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using ++,
compressed air.
-J
Caution
1. Cover with rags to prevent the piston from popping
out.
2. Apply compressed air slowly to prevent brake fluid
from splashing.
CLUTCH - Clutch Release Cvlinder 6-15
INSPECTION NWLCAV
.- (1) Check the inner surface of the release cylinder for

Piston scratches or irregular wear.
\ (2) Replace if the piston cup outer circumference is scratched
or shows signs of fatigue, or if there is excessive wear of
the lip where indicated in the figure.
*
@
CUP
6CLOOO3
SERVICE POINTS OF REASSEMBLY NO6LDAB
5. APPLICATION OF FLUID TO PISTON AND CUP

Apply specified brake fluid to the release cylinder inside and
outer surface of the piston and piston cup and push the
piston cup assembly in the cylinder.
Specified brake fluid: MOPAR Brake Fluid/Conforming
to DOT3
DCLOOE ,
6-16 C L U T C H - Clutch Cover and Disc
CLUTCH COVER AND DISC

l Removal of the transaxle assembly
(Refer to GROUP 21 - Transaxle
assembly.)
*Installation of the transaxle assem-
bly (Refer to GROUP 21 -Transaxle 35-42 Nm
assembly.) 25-30 ft.lbs.\
6CLOOO4
15-22 Nm
11-16 ft.lbs.
Removal steps
+e l 1. Clutch cover assembly
+**a 2. Clutch disc
3. Return clip
l + 4. Clutch release bearing
l * 5. Release fork FyEeverse the removal procedures to reinstall.
6. Fulcrum (2) 4e : Refer to “Service Points of Removal”.
7. Release fork boot (3) I)4 : Refer to “Service Points of Installation”
CLUTCH - Clutch Cover and Disc 647
SERVICE POINTS OF REMOVAL NO6OSAH
1. REMOVAL OF CLUTCH COVER ASSEMBLY/P.

CLUTCH DISC
Diagonally loosen bolts which attach clutch cover to
flywheel. Back off bolts in succession, one or two turns at a
time, to avoid bending cover flange.
Caution
DO NOT clean clutch disc or release bearing with
cleaning solvent.
08A0038
INSPECTION NlNGCAB
CLUTCH COVER ASSEMBLY

l Check the diaphragm spring end for wear and uneven
height.
Replace If wear is evident or height difference exceeds the
limit.
Limit : 0 . 5 mm (.02 in.)
l Check the pressure plate surface for wear, cracks and color
change.
l Check the strap plate rivets for looseness and replace the
clutch cover assembly if loose.
CLUTCH DISC
l Check the facing for loose rivets, uneven contact, deteriora-
tion due to seizure, adhesron of oil or grease and replace
the clutch disc if defective.
l Measure the rivet sink and replace the clutch disc if it is out
of specification.
6CLOO3 Limit : 0 . 3 mm (.012 in.)

l Check for torsion spring play and damage and if defective,
replace the clutch disc.
l Combine the clutch disc with the input shaft and check
sliding condition and check for play in the rotating direction.
If it does not slide smoothly, check after cleaning and
reassembling. If the play IS excessive, replace the clutch
drsc and/or the input shaft.
CLUTCH RELEASE BEARING

Caution
The release bearing is packed with grease, so don’t use
cleaning oil, etc. to clean it.
l Check for beanng heat damage, other damage, abnormal

noise and/or improper rotation. Also check whether or not
there IS wear at the point of contact with the diaphragm
spring.
l If there is abnormal wear at the pornt of contact with the
release fork, replace the bearing.
RELEASE FORK
l If there is abnormal wear at the pornt of contact with the
bearing, replace the release fork.
6-18 CLUTCH - Clutch Cover and Disc
SERVICE POINTS OF INSTALLATION NWGDAT
5. A,PPLlCATlON OF GREASE TO RELEASE FORK Ai&

(1 ) Apply a coating of the specified grease to the point of i(
contact with the fulcrum and the point of contact with
the release bearing.
Specified grease: MOPAR Multi-mileage Lubricant

Part Nq.2525035 or equivalent
Caution
When installing the clutch, apply grease to each
part, but be careful not to apply excessive grease;
excessive grease will cause clutch slippage and
shudder.
(2) Apply a coating of the specified grease to the end of the

release cylinder’s push rod and to the push rod hole in
the release fork.

I 6CLO33
4. APPLICATION OF GREASE TO CLUTCH RELEASE

BEARING
Pack the inner surface of the clutch release bearing and the
groove with the specified grease. L4r
Specified grease: MOPAR Multi-mileage Lubricant _
Caution
For the release bearing of a resin sleeve, grease must
not be applied to the sleeve part.
2. APPLICATION OF GREASE TO CLUTCH DISC/ 1.

CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.

Clutch disc Part No.2525035 or equivalent
(2) Using the special tool (clutch disc center guide),

position the clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.
Clutch cover
T& assembly
6CLO26
7-l
COOLING
CONTENTS
ENGINE COOLANT TEMPERATURE GAUGE Sealant .......................................................... 4

UNIT, ENGINE COOLANT TEMPERATURE Service Specifications ................................... 2
SENSOR AND ENGINE COOLANT
TEMPERATURE SWITCH ................................ 34
THERMOSTAT ................................................. 15
RADIATOR ....................................................... 12
TROUBLESHOOTING ............. . ........................ 5
RADIATOR FAN MOTOR ASSEMBLY .......... 15
No rise in temperature ................................ 5
SERVICE ADJUSTMENT PROCEDURES.. ..... 8 Overheat ....................................................... 5
Alternatormater Pump Drive Belt Tension
Adjustment .................................................... 9 WATER HOSE AND WATER PIPE
<1.8L Engine> ................................................ 25
Alternator/Water Pump Drive Belt Tension
Inspection.. .................................................... 8
WATER HOSE AND WATER PIPE
Cap Pressure Test ....................................... 8 <2.0L DOHC Engine (Non-Turbo)> ............. 28
Engine Coolant Concentration Test ............. 8
Engine Coolant Leak Check ........................ 8 WATER HOSE AND WATER PIPE
<2.0L DOHC Engine (Turbo) > .................... 31
Engine Coolant Replacement ....................... 8
WATER PUMP <1.8L Engine> ..................... 17
SPECIFICATIONS ............................................. 2
General Specifications .................................. 2 WATER PUMP <2.0L DOHC Engine> ......... 21
Lubricant ....................................................... 4
7-2 COOLING - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NQ7cA- I Ic
Cooling method Water-cooled, pressurized, forced circulation

with electrical fan
Radiator
Type Pressurized corrugated fin type
Radiator fan motor
Type Direct current ferrite type
Water pump
Type Impeller of centrifugal type
Thermostat
Type Wax pellet type with jiggle valve
Identification mark 88 (Stamped on flange)
Drive belt
Type V-ribbed belt
Engine coolant temperature gauge unit
We Thermistor type
Engine coolant temperature sensor (Engine control)
Type Thermistor type
Engine coolant temperature switch (Air conditioner)
We Thermistor type
SERVICE SPECIFICATIONS N07CB.-
Standard value
Range of coolant antifreeze concentration % 30-60
Thermostat
Valve opening temperature of thermostat “C (“F) 88 (190)
Full-opening temperature of thermostat “C (“F) 100 (212) or more
Opening pressure of cap high pressure valve kPa (psi) 75-105 (11-15)
Therm0 sensor (on radiator)
Operating temperature
OFF + ON “C (“F) 82-88 (180-190)
ON --P OFF “C (“F) 78 (172) or less
Engine coolant temperature gauge unit
Resistance
A t 70°C (158°F) Q 104f 13.5
Engine coolant temperature sensor (Engine control)
Resistance
A t 20°C (68°F) kQ 2.45 I!I 0.24
A t 80°C (176°F) Q 296 + 32
ON -+ OFF operating temperature “C (“F) 112-l 18 (234-244)
Limit
Opening pressure cap high pressure valve kPa (psi) 65 (9.2)
COOLING - Specifications 7-3
TORQUE SPECIFICATIONS N07CG.
Items Nm ft.lbs.
R a d i a t oupper
r insulator 9-14 7-10
Thermosensor to radiator 3-4 2-3
Automatic transaxle oil cooler hose cramp 4-6 3-4
Automatic transaxle oil cooler hose mounting bolt 3-5 2-4
Water outlet fitting bolts 17-20 12-14
Engine mount insulator nut (large) 60-80 43-58
Engine mount insulator nut (small) 30-40 22-29
Engine mount bracket to engine 50-65 36-47
Bracket between engine mount bracket and engine 17-26 12-19
Tension pulley bracket for air conditioner <1.8L Engine> 18-22 13-15
Water pump installation bolt
Bolt head mark “4T” 12-15 9-11
Bolt head mark “7T” 20-27 14-20
Water pump
pulley bolt 8-10 6-7
Damper pulley, crankshaft pulley
<1.8L Engine> 15-18 11-13
<2.0L DOHC Engine> 20-30 14-22
Timing belt front upper cover installation bolt IO-12 7-9
Timing belt front lower cover installation bolt 10-12 7-9
Crankshaft sprocket installation bolt 110-130 80-94
Timing belt B tensioner 15-22 11-16
Tension pulley bracket for air conditioner <2.0L DOHC Engine> 23-27 17-20
Automatic tensioner installation bolt 20-27 14-20
Tensioner pulley installation bolt 43-55 31-40
Oil level gauge 12-15 9-11
Front exhaust pipe to exhaust manifold
<FWD> 30-40 22-29
<AWD> 40-60 29-43
Front exhaust pipe bracket 30-40 22-29
Exhaust manifold cover (A)

Flange bolt: 8 x 12 mm (.31 x .47 in.) 27-33 20-24
Washer assembled bolt: 6 x 14 mm (.24 x .55 in.) 8-10 6-7
<2.0L DOHC Engine (Non-Turbo)> 12-15 9-11
Exhaust manifold cover (8) <Non-Turbo> 12-15 9-11
Heat protecter (A) <Turbo> 12-15 9-11
Heat protecter (B) <Turbo> 12-15 9-l 1
Exhaust manifold to cylinder head
<1.8L Engine> 15-20 11-14
<2.0L DOHC Engine> 25-30 18-22
Engine hanger to engine bracket 12-15 9-11
JVater inlet pipe installation bolt
Transaxle side 43-55 31-40
Engine block side <1.8L Engine> IO-12 7-9
<2.0L DOHC Engine> 12-15 9-11
'ower steering oil pump to oil pump bracket 35-45 25-33
‘ower steering oil pump bracket to engine 25-33 18-24
7-4 COOLING - Specifications
Items Nm ft.lbs. _1
Exhaust manifold to turbocharger 55-65 40-47

Oil return pipe 8-10 6-7
Water pipe (A) to turbocharger 35-50 25-36
Water pipe (A) mounting bolt 10-12 7-9
Water pipe (B) to turbocharger 35-50 25-36
Water pipe (B) to water inlet pipe 40-50 29-36
Water pipe to engine
Mounting bolt (M8) 12-15 9-11
Mounting bolt (M6) 10-12 7-9
Water pipe to turbocharger 8-10 6-7
Eye bolt (oil pipe) 14-19 10-14
Exhaust pipe support bracket 30-42 22-30
Exhaust pipe support bracket to front exhaust pipe 30-40 22-29 .’
Engine coolant temperature gauge unit 10-12 7-9
Engine coolant temperature sensor (Engine control) 20-40 14-29
Engine coolant temperature switch (Air conditioner) 30-40 22-29
LUBRICANT
Item Specified lubricant Quantity
Engine coolant High quality ethylene glycol antifreeze coolant 
6.2 liters
6.5 qts.
<2.0L DOHC Engine>
7.2 liters
7.6 qts.
SEALANT NO7CE-.
Item Specified adhesive
Engine coolant temperature gauge unit MOPAR Part No.4318034 or equivalent

-Engine coolant temperature sensor (Engine control)
COOLING - Troubleshootina 7-5
TRO,UBLESHOOTlNG
Overheat Insufficient engine coolant Replenish
Too high an anti-freeze concentration Correct anti-freeze

concentration
Loose or broken drive belt Replace
Inoperative electric cooling fan

Faulty thermosensor Replace
Faulty electrical motor Replace
Faulty radiator fan relay Replace
Damaged or blocked (insufficiently ventilated) radiator fins Correct
Water leaks
Damaged radiator core joint Replace
Corroded or cracked hoses Replace
(radiator hose, heater hose, etc.)
Loose bolt or leaking gasket in water outlet fitting Correct or replace
(thermostat)
Loose water pump mounting bolt or leaking gasket Correct or replace
Faulty cap valve or setting of spring Replace
Loose intake manifold bolts or leaking from gasket Retorque bolts or replace
gasket
Cracked intake manifold Replace
Faulty automatic transaxle oil cooler operation

Blocked or collapsed hose and pipe Replace
Loose hose and pipe connection Correct
Faulty thermostat operation Replace
Faulty water pump operation Replace
Water passage clogged with slime or rust deposit or Clean

foreign substance
Jo rise in temperature Faulty thermostat Replace

7-6 COOLING - Troubleshooting
CIRCUIT DIAGRAM
IGNI: ON
MAIN FUSIB: : LINK@ SWIT( (IG2) SUB FUSIBLE LINK @
0
A-18X
CONDENSER FAN
A-03X MOTOR RELAY
.----- I2
34
lm
IN
1
A-22 1
12
CONDENSER
A-20X ,
P
I!3
CONDENSER
RESISTOR
CONDENSER'
( FAN MOTOR,
A-32
;;aIATOR ci 'C-72
ASSEMBLY
RADIATOR
FAN
MOTOR (
t----l
TH RMO
BE 80R
CONDENSER
FAN MOTOR
lal
12
34
$l
2A-21
I Ed3
I
B4SB
Q
A-32
A-40 0
II
I
i
I
0
A
6
KX35-AC-U0802-NC
COOLING - Troubleshooting 7A7
OPERATION TROUBLESHOOTING HINTS

1. When the output of the air conditioner 1. Neither the radiator fan nor condenser fan
*-- control unit is “LO” (OV) rotate at all.
(when the compressor magnet clutch is l Check sub fusible link No.3.
deenergized)
2. Only the condenser fan does not operate.
l When the ignition switch is at “ON” , and if
l Check dedicated fuse No.5.
engine coolant temperature rises to 85°C
(185”F), the thermosensor contacts close, 3. The radiator fan and condenser fan do not
causing current to flow through the radiator operate in the low speed mode, but operate
fan motor relay (coil), thermosensor and otherwise.
ground, causing the radiator fan motor relay (1)The A/C compressor magnet clutch does not
contacts to close. enter the “ON” state.
l Current flows through the radiator fan motor l Check whether the output of the air con-
relay contacts, radiator fan motor and ground, ditioner control unit is available.
causing the radiator fan motor to rotate.
NOTE
2. When the output of the air conditioner For troubleshooting of the air conditioner
control unit is “HI” (approx. 12V) control unit, refer to GROUP 24.
(when the compressor magnet clutch is (2)The A/C compressor magnet clutch enters
energized) the “ON” state.
l If the therm0 sensor is “ON” when the l Check the resistor.
engine coolant temperature exceeds 85°C
(185°F). the condenser fan motor control relay
is also “ON”, thus the condenser fan as well
as the radiator fan start rotating at a high
speed.
Conditions under which the Air Conditioner Control Unit Outputs a “HI” Signal
Ignition switch (IG2) ON Remarks

l If any of the switches and sensors is OFF,
Blower switch ON the air conditioner control unit will
output a “LO” signal (OV).
Air conditioner switch ON
Compressor magnet clutch ON
Fan Operating Mode
Switch conditions Fan rotating condition
Air conditioner switch Therm0 sensor Cooling (radiator) fan Condenser fan
LO (OV) OFF OFF OFF

LO (OV) ON HIGH OFF
HI (12V) OFF LOW LOW
HI (12V) ON HIGH HIGH
_- NOTE
The therm0 sensor is ON when the temperature reaches 85°C (185°F) or more.
7-8 COOLING - Service Adjustment Procedures

ENGINE COOLANT LEAK CHECK NO7FAAE
1. Loosen cap.
2. Confirm that the engine coolant level is up to the filler neck.
3. Install a adapter to the water outlet fitting and apply 160
kPa (23 psi) pressure. Hold pressure for tvvo minutes, while
checking for leakage from the radiator, hose or connec-
tions
Caution
Be sure to completely clean away moisture from the
places checked.
When the tester is removed, be careful not to spill any
engine coolant from it.
Be careful, when installing and removing the tester and
when testing, not to deform the water outlet fitting.
4. If there is leakage, repair or replace the appropriate part.
CAP PRESSURE TEST NO’IFBAG
1. Use a special tool to attach the cap to the tester.

2. Increase the pressure until the indicator of the gauge stops
moving.
Limit: 65 kPa (9.2 psi)
Standard value: 75-105 kPa (11-15 psi)
3. Replace the cap if the reading does not remain at or above
the limit.
NOTE
04DooE Be sure that the cap is clean before testing, since rust or
other foreign material on the cap seal will cause an
improper indication.
ENGINE COOLANT REPLACEMENT NO’IFCAC
Refer to GROUP O-Cooling System.
ENGINE COOLANT CONCENTRATION TESTmAG

Refer to GROUP O-Selection of Engine Coolant.
ALTERNATOR/WATER PUMP DRIVE BELT TEN-

SION INSPECTION NO7FEAG
Caution
If the belt slips or squeaks, check the belt tension and also
check the belt for wear, damage and breakage and check
the pulleys for damage.
COOLING - Service Adjustment Procedures 7-9
(1) Place straight edge as shown in the illustration.
(2) Measure the deflection with a force of 100 N (22 lb4
applied to belt mid-point between water pump pulley and
alternator pulley. If the standard value is not obtained, make
adjustment.
Standard value:
 8.0-11.0 mm (.315-433 in.)
<2.0L DOHC Engine> 9.0-I 1.5 mm (.354-.453 in.)
Alterhator
pulley
6COOOO9
(3) Use a tension gauge to check the belt tension. If the

standard value is not obtained, make adjustment.
When tension gauge is used, the tension may be measured
between any two pulleys.
Standard value: 250-500 N (55-110 Ibs.)
Spindle
l-
ALTERNATOR/WATER PUMP DRIVE BELT TEN-

SION ADJUSTMENT ruo7FFAl
Caution
Excessive belt tension will cause damage to alternator and
water pump pulley bearings, while on the other hand,
loose belt tension will produces slip.
Therefore, be sure to adjust the belt tension to proper
value.


(1) Loosen the nut on the alternator support bolt.
(2) Loosen the alternator brace bolt.
(3) Make sure that the belt is properly installed in pulley

groove.
Incorrect Correct Incorrect
6COO37
-
COOLING - Service Adjustment Procedures
(4) Move the alternator to adjust so that the amount of
deflection is the standard value.
Standard value:
New belt 6.5-8.0 mm (.256-.315 in.)
Used belt 9.5 mm (.374 in.)
Deflec :tion
100N
(22 Ibs.)
Alternator y
pulley
6COOOO9
(5) On using tension gauge, move the alternator to adjust

deflection to standard value.
Standard value:
New belt 600flOO N (132+22 Ibs.)
Used belt 400 N (88 Ibs.)
(6) After completion of adjustment, tighten alternator brace
bolt and alternator brace bolt nut to the specified torque.
Spindle , (7) If new belt has been installed, run engine for more than 5
minutes.
OlLO149
Then follow “V-RIBBED BELT DEFLECTION CHECK”
Hook
procedure to make sure that the belt has proper deflection.
<2.0L DOHC Engine>
(1) Loosen the alternator pivot nut.
(2) Loosen the belt tension adjuster lock bolt.
(3) Release tension by rotating the adjuster bolt counterclock-
wise.
(4) Remove and install the alternator and water pump drive
belt.
(5) Make sure the V-ribbed type drive belt is properly installed
in pulley grooves.
Incorrect Correct Incorrect
6COO37
-
COOLING - Service Adjustment Procedures 7-m
(6) Adjust belt deflection by tightening adjust bolt. :
Turn adjuster bolt clockwise to increase the belt tension
and turn adjuster bolt counterclockwise to decrease the
belt tension.
Standard value:
New belt 7.5-9.0 mm (.295-.354 in.)
Used belt 10.0 mm (.394 in.)
1 (7) On using tension gauge, move the alternator to adjust

deflection to standard value.
Standard value:
New belt 600+100 N (132f22 Ibs.)
Used belt 400 N (88 Ibs.)
(8) Tighten in order, first, adjuster lock bolt then alternator
pivot nut to the specified torque.
(9) If new belt has been installed, run engine for more than 5
minutes. Then follow “DRIVE BELT TENSION INSPEC-
TION” procedure to make sure that the belt has proper
tension and readjust if necessary.
7-12 COOLING - Radiator
RADIATOR
@Draining of the Engine Coolant
(Refer to GROUP O-Maintenance (Refer to GROUP II-Air Cleaner.)
Service.) <Turbo>
@Removal of Air Cleaner Bracket ORefilling of the Engine Coolant
(Refer to GROUP 11 -Air Cleaner.) I I (Refer to GROUP O-Maintenance
<Turbo> Service.)
*Checking Automatic Transaxle Fluid
Level and Refilling If Necessary
9-14 Nm _
04AOOS7
4-6 Nm
3-4 ft.lbs.
4-9 Nm
Removal steps 3-4 ft.lbs.
1 Drain plug 07A0049
2. Cap
3.. Overflow tube
4. Water level switch connector 13. Radiator assembly
5. Reserve tank 14. Condenser fan motor assembly
~~ l + 6. Radiator upper hose <Vehicles with air conditioner>
+e e+ 7. Radiator lower hose 15. Radiator fan motor assembly
*I) 8. Automatic transaxle oil cooler hoses 16. Thermosensor
<Vehicles with Non-Turbo (A/T)> 17. Lower insulator
9. Therm0 sensor connector
IO. Radiator fan motor connector NOTE
11. Condenser fan motor connector (1) Reverse the removal procedures to reinstall.
<Vehicles with air conditioner> (2) +e : Refer to “Service Points of Removal”.
12. Upper insulator (3) l + : Refer to “Service Points of Installation”
COOLING - Radiator 7-13
Mating marks
SERVICE POINTS OF REMOVAL N07QBAH
6. REMOVAL OF RADIATOR UPPER HOSE/7. RADIATOR

LOWER HOSE
After making mating marks on the radiator hose and the
hose clamp, disconnect the radiator hose.
8. DISCONNECTION OF AUTOMATIC TRANSAXLE OIL

COOLER HOSES
Use a plug or otherwise cover the hose and nipple part of
the radiator so that dust, dirt, foreign materials, etc. do not
enter after the hose has been disconnected from the
radiator.
INSPECTION No7OcAM
l Check for foreign material between radiator fins.

l Check the radiator fins for bent, or damage.
l Check the radiator for corrosion, damage rust or scale.
l Check the radiator hoses for cracks, damage or deteriora-
tion.
l Check the reserve tank for damage.
l Check the automatic transaxle oil cooler hoses for cracking,
damage or deterioration.
RADIATOR FAN MOTOR INSPECTION

(1) Check to be sure that the radiator fan rotates when batten/
voltage is applied between terminals (as shown in the
figure).
(2) Check to see that abnormal noises are not produced, while
motor is turning.
THERM0 SENSOR INSPECTION

Check for continuity with the therm0 sensor in hot water.
NOTE
Immerse therm0 sensor in hot water up to mounting thread to
check for continuity.
04A0020
7-14 COOLING - Radiator
Standard value:
Continuity at 82-88X (180-190°F) . . . . . . . . . . . at A point
No continuity at 78°C (172°F) or less . . . . . . . . at 6 point .r;;;
h
A
OFF
ON --- ,
B Water
temperature
16v1100
RADIATOR FAN MOTOR RELAY INSPECTION

(1) Remove radiator fan motor relay from the relay box located
at the right side in the engine compartment.
(2) Check for continuity between the terminals when the

battery power-supply is applied to terminal 0, and terminal
@ is grounded.
When current Between Continuity

flows terminals l-3
When no
current flows
16LO312
1 Mating marks
SERVICE POINTS OF JNSTALLATION NOMDAF
7. INSTALLATION OF RADIATOR LOWER HOSE/

6. RADIATOR UPPER HOSE
Align the mating marks on the radiator hose and hose
clamp and then connect them; then, applying force in the ~
direction indicated by the arrow in the illustration, seat the 1
clamp to the trace marks of the previous connection.
Caution
Be sure to install the hose clamps at the trace marks of
the previous connection.
COOLING - Radiator Fan Motor AssemblvIThermostat 7-15
RADIATOR FAN MOTOR ASSEMBLY NOTTA-
Disassembly steps
1. Fan
2. Radiator fan motor
3. Shroud
NOTE
Reverse the disassembly procedures to reassemble.
04AOO92
THERMOSTAT
REMOVAL AND INSTALLATION N07G6-
< 1.8L DOHC

17-20 Nm
P 12-14 ft.lbs.
1 1 2 - 1 4 ftlbs. 1
4 4 Removal steps
1. Cap
m5 al5 +e l 4 2. Connection for radiator upper hose
3. Connection for overflow tube
6 6 ;. ra;t;er;utlet fitting
l + 6: Thermostat
NOTE
2 (2) ~~ : Refer to “Service Points of Removal”.
04Aoo91 (4) 19 : Non-reusable parts
Mating marks SERVICE POINTS OF REMOVAL NO7GCFU
2. DISCONNECTION OF RADIATOR UPPER HOSE

Radiator hose
04A009E
7-16 COOLING - Thermostat
INSPECTION y+w
l Check that valve closes tightly at room temperature.
l Check for defects or damage.
l Check for rust or encrustation on valve. Remove if any.
l Immerse thermostat in container of water. Stir to raise
water temperature and check that thermostat opening
valve temperature and the temperature with valve fully
open [valve lift-over 8 mm (.31 in.)] are at the standard
value.
Standard value:
Opening valve temperature 88°C ( 190°F)
Full-open temperature 100°C (212°F)
NOTE
Measure valve height when fully closed. Calculate lift by
measuring the height when fully open.
Fully
closed
position
ve lift
04UOO18
<1.8L Engine> SERVICE POINTS OF INSTALLATION NOlGEAG

6. INSTALLATION OF THERMOSTAT
Install the thermostat so that the flange fits perfectly to the
recessed seat of the thermostat or thermostat housing.
<2.0L DOHC Engine:

I
2. CONNECTION OF RADIATOR UPPER HOSE

Mating marks
clamp and then connect them; then, applying force in the
direction indicated by the arrow in the illustration, seat the
Caution
04A0099 )
COOLING - Water Pump <1.8L Engine> 7-17
WATER PUMP 4.8L Engine>
- REMOVAL AND INSTALLATION NOlMB-A
*Draining of the Engine Coolant

(Refer to GROUP O-Maintenance
30-40 Nm
Post-installation Operation 0
l installation of the Under Cover 22-2g Fbs.
@Supplying of the Engine Coolant
Service.)
@Engine Adjustment
(RR:; to GROUP g-Engine Adjust- 60-80 Nm
43-58 ft.lbs.
8-10 Nm
c.
6-7 ftlbs.
4 8
5 - 1 8 Nm
1-13 ft.lbs.
18-22 Nm OlAO566
13-15 ft.lbs.
Removal steps 7. Water pump pulley (Power steering)
1. Clamp part of hoses (Power steering) Water pump pulley
4+ 2. Engine mount bracket Damper pullev
l + 3. Drive belt (Air conditioner) Adapter. ’
I)+ 4. Drive belt (Power steering) Crank shaft pulley.
-_
4+ l + 5. Drive belt
6. Tension tx~llev bra&&
r--‘-- I -‘--‘.--
I\lnTF
I.VIL

I?\
\-, CI
--. Refer
I.VIw, tn
.” “Smvirr
..-..,u; rh:-*-
r”llllb “-‘ I “allI”\
D---./al”,
(3) +4 : Refer to “Service_ Points
- .,.__ -.nf _.._
Instalk
.-Jion”.
7-18 COOLING - Water Pump <1.8L Engine>
lo-12 Nm
7-9 ft.lbs.
OlA05813
17
Removal steps
12. Spark plug cable 23. Alternator brace
+e l 4 13. Rocker cover l + 24. Water pump
14. Rocker cover gasket 25. Water pump gasket
l + 15. Semi-circular packing l + 26. O-ring
~~ e+ 16. Timing belt front upper cover
l 17. Timing belt front lower cover NUlt
+e l 18. Timing belt (I) Reverse the removal procedures to reinstall.
19. Crankshaft sprocket (2) ** : Refer to “Service Points of Removal”.
l 20. Flange (3) l 4 : Refer to “Service Points of Installation”.
21. Timing belt B tensioner (4) m : Non-reusable parts
l I) ~~ 22. Timing belt B
COOLING - Water Pump <1.8L Engine> 749
SERVICE POINTS OF REMOVAL NO’IMCAG
2. REMOVAL OF ENGINE MOUNT BRACKET

(1) Place a wooden block at the oil pan part of the engine, and
then jack up the vehicle.
Caution
Jack up carefully, so as not to apply a load to each part.
(2) Remove the engine mount bracket.
5. REMOVAL OF DRIVE BELT

Before removing the V-ribbed belt, loosen the water pump
pulley installation bolt.
13. REMOVAL OF ROCKER COVER/16. TIMING BELT
FRONT UPPER COVER/ 18. TIMING BELT
For information concerning the removal of the rocker cover,
the timing belt front upper cover, and the timing belt, refer
to GROUP g-Timing Belt.
22. REMOVAL OF TIMING BELT B
For information concerning the removal of the timing belt
B, refer to GROUP g-Timing Belt B.
INSPECTION N07MDAL
V-RIBBED BELT
Check following items and replace if faulty.
l Check belt surface for damage, peeling or cracks.
l Check belt surface for oil or grease.
l Check belt rubber for wear or brittleness.
Core wire l Check the pulleys for cracks or damage.
\
Adhesive rubber
\
Rib rubber
1 coo21
WATER PUMP
l Check each part for cracks, damage or wear, and replace
the water pump assembly if necessary.
l Check the bearing for damage, abnormal noise and
sluggish rotation, and replace the water pump assembly if
necessary.
l Check the seal unit for leaks, and replace the water pump
assembly if necessary.
l Check for water leakage. If water leaks from hole “A”, seal
unit is leaking. Replace as an assembly.
7-20 COOLING - Water Pump <1.8L Engine>
SERVICE POINTS OF INSTALLATION N07ME40a
l-----r,
a Water pump
*< 26. INSTALLATION OF O-RING
s
O-ring
Insert the O-ring to the water inlet pipe, and coat the,buter ,
circumference of the O-ring with water.
// Water pipe By coating with water, the insertion to the water pump will
become easier.
Caution
1. Care must be taken not to permit engine oil or other
greases to adhere to the O-ring.
04ROO24 2. When inserting the pipe, check to be sure,that there
J
is no sand, dirt, etc. on its inner surface.
24. INSTALLATION OF WATER PUMP,

(1) Clean both gasket surfaces of water pump body and
cylinder block.
(2) Install new water pump gasket and water pump
assembly and tighten the bolts.
Identification mark
Bolt diameter (d) Torque
x length (e) mm (in.) Nm (ftlbs.) I
04lJoo25
I 1 I 4 8 x 28 (.31 x 1.1) 112-15 (9-10) 1
Alternater brace
I 2 I 7 1 8 x 7 0 (.31 x 2 . 7 6 ) 120-27 (15-19)(
3 4 8 x 55 (.31 x 2.17)
12-15 (9-10)
4 4 8 x 28 (.31 x 1.1) I
22. INSTALLATION OF TIMING BELT B/20. FLANGE -

For information concerning the installation of the timing
belt B and the flange, refer to GROUP g-Timing Belt B.
18. INSTALLATION OF TIMING BELT/l7. TIMING BELT
4 04uoo22 FRONT LOWER COVER/lG. TIMING BELT FRONT UP-
PER COVER/ 15. SEMI-CIRCULAR PACKING / 13.
ROCKER COVER
belt, the timing belt front lower cover, the timing belt front
upper cover, the semi-circular packing, and the rocker
cover, refer to GROUP g-Timing Belt.
5. DRIVE BELT TENSION ADJUSTMENT
Refer to P.7-9.
4. DRIVE BELT TENSION ADJUSTMENT <POWER
STEERING>
Refer to GROUP 19-Service Adjustment Procedures.
3. DRIVE BELT TENSION ADJUSTMENT <AIR
CONDITIONER>
Refer to GROUP 24-Service Adjustment Procedures,
COOLING - Water Pump <2.0L DOHC Engine> 7-21
WATER PUMP <2.0L DOHC Engine>

No7Ms-B
--- REMOVAL AND INSTALLATION
1
Pre-removal Operation 50-65 Nm
@Removal of the Under Cover 36-47 ft.lbs.
l Draining of the Engine Coolant
Service.)
60-60 Nm
l installation of the Under Cover
l supplying of the Engine Coolant
Service.)
*Engine Adjustment
(Ri+&; to GROUP g-Engine Adjust-
I
I-40 Nm
17-26
12-19 ,“k.
!-29 ft.lbs.
OlAO560
20-27 Nm
14-20 ft.lbs.
lo-12 Nm
7 - 9 ft.lbs. 4 3 - 5
31-4
” .““*wY
23-27 Nm ” 2’0 -30
-- -~Nm
..
17-20 ft.lbs. 14-22 ft.ll 3s.
Removal steps l + 10. Timing belt upper cover
I. Clamp part of hoses (Power steering) I)4 11. Timing belt lower cover
+I) l + 12. Automatic tensioner
+* 2. Engine mount bracket 13. Tensioner pulley
l + 3. Drive belt +I) l + 14. Timing belt
_ e+ 4. Drive belt (Power steering)
5. Tension pulley bracket
I)4 6. Drive belt (Air conditioner) NOTE
7. Water pump pulley (1) Reverse the removal procedures to reinstall.
8. Water pump pulley (Power steering) (2) +e : Refer to “Service Points of Removal”.
9. Crankshaft pulley (3) l 4 : Refer to “Service Points of Installation”
7-22 C O O L I N G - Water Pump <2.0L DOHC Engine>
20-27-Nm 12-15 Nm
14-20 ft.lbs. 9- 11 ftlbs. \, /”
110-130 Nm @
80-94 ftlbs. -
04A0094
15. Crankshaft sprocket

l a 16. Flange
17. Timing belt B tensioner
4e l + 18. Timing belt B NOTE
19. Alternator brace (I) Reverse the removal procedures to reinstall.
l 4 20. Water pump (2) 4* : Refer to “Service Points of Removal”.
21. Water pump gasket (3) ** : Refer to “Service Points of Installation”.
I)* 22. O-ring (4) m : Non-reusable parts
SERVICE POINTS OF REMOVAL NO’IMCAH

(1) Place a wooden block at the oil pan part of the engine, and
then jack up the vehicle.
Caution cylb
Jack up carefully, so as not to apply a load to each part. .__
(2) Remove the engine mount b r a c k e t .
C O O L I N G - Water Pump <2.0L DOHC Engine> 7-2’3
12. REMOVAL OF AUTOMATIC TENSIONERI14. TIMING
BELT
For information concerning removal of the automatic
tensioner and the timing belt, refer to GROUP g-Timing
Belt.
18. REMOVAL OF TIMING BELT B
For information concerning the removal of timing belt 6,
refer to GROUP g-Timing Belt B.
INSPECTION No7mDA.l
V-RIBBED BELT
Quality canvas
Check following items and replace if faulty.
l Check belt surface for damage, peeling or cracks.
l Check belt surface for oil or grease.
l Check belt rubber for wear or brittleness.
‘0 Check the pulleys for cracks or damage.
Core wire
\
Adhesive rubber
\
Rib rubber
lCOO2I
WATER PUMP
l Check each part for cracks, damage or wear, and replace
the water pump assembly if necessary.
l Check the bearing for damage, abnormal noise and
sluggish rotation, and replace the water pump assembly if
necessary.
l Check the seal unit for leaks, and replace the water pump
assembly if necessary.
l Check for water leakage.
SERVICE POINTS OF INSTALLATION N07MEAN
22. INSTALLATION OF O-RING

Insert the O-ring to the water inlet pipe, and coat the outer
By coating with water, the insertion to the water pump will
become easier.
Caution
1. Care must be taken not to permit engine oil or other
MRM2. greases to adhere to the O-ring.
2. When inserting the pipe, check to be sure that there
is no sand, dirt, etc. on its inner surface.
7-24 COOLING - Water Pump <2.0L DOHC Engine>
20. INSTALLATION OF WATER PUMP
(1) Clean both gasket surfaces of water pump body and jir,
cylinder block.
(2) Install new water pump gasket and water pump ’
assembly and tighten the bolts.
No, Identification Bolt diameter (d) Torque

mark x length (I?) mm (in.) Nm (ft.lbs.1
Identification mark 1 4 8 x 14 (.31 x .55)
2 4 8 x 22 (.31 x .87) 12-15 (g-10)

4lternater brace 3 4 8 x 30 (.31 x 1.18)
4 7 8 x 65 (.31 x 2.56) 20-27 (15-191
5 4 8 x 28 (.31 x 1.10) 12-15 (g-10)
6COOOlO
18. INSTALLATION OF TIMING BELT B/16. FLANGE

belt B and the flange, refer to GROUP g-Timing Belt B.
14. INSTALLATION OF TIMING BELT/lZ. AUTOMATIC 6
TENSlONNER/ 11. TIMING BELT LOWER COVER/ -
10. TIMING BELT UPPER COVER
For information concerning installation of the timing belt,
the automatic tensioner, the timing belt lower cover, and
the timing belt upper cover, refer to GROUP g-Timing Belt.
6. DRIVE BELT TENSION ADJUSTMENT <AIR
CONDITIONER>
4. DRIVE BELT TENSION ADJUSTMENT <POWER
STEERING>
Refer to GROUP 1 g-Service Adjustment Procedures.
3. DRIVE BELT TENSION ADJUSTMENT
Refer to P.7-9.
COOLING - Water Hose and Water Pipe <1.8L Engine>
WATER HOSE AND WATER PIPE <1.8L Engine>

_- REMOVAL AND INSTALLATION NO’IIA-A
27-33 Nm
20-24 ftlbs.
12-15 Nm
s- 11 ft.lbs.
Removal steps
1 Air intake hose
2. Engine oil level gauge guide
3. O-ring
4. Self locking nut
5. Gasket
6. Oxygen sensor harness connector
7. Exhaust manifold cover (A)
8. Engine hanger
9. Exhaust manifold NOTE
IO. Exhaust manifold gasket (1) Reverse the removal procedures to reinstall.
11. Exhaust manifold cover(B) (2) m : Non-reusable parts
7-26 COOLING - Water Hose and Water Pipe <1.8L Engine>
43-55 Nm
31-40 ft.lbs.
lo‘-12 Nm
7 - 9 ft.lbs.
12. Connection for heater hose

13. Water by-pass hose NOTE
14. Water hose (1) Reverse the removal procedures to reinstall.
++ e+ 15. Connection for radiator lower hose (2) +e : Refer to “Service Points of Removal”.
l + 16. Water inlet pipe (3) l * : Refer to “Service Points of Installation”
l * 17. O-ring (4) q : Non-reusable parts
Mating marks
SERVICE POINTS OF REMOVAL NO7ISACl
15. DISCONNECTION OF RADIATOR LOWER HOSE

Hose
Radiator hose ’
04AOOSS
INSPECTION NO7KAAaI
WATER PIPE AND HOSE INSPECTION

Check the water pipe and hose for cracks, damage, clog and
replace them if necessary.
COOLING - Water Hose and Water Pipe <1.8L Engine> 7-27
r
SERVICE POINTS OF INSTALLATION NO7lDAJl
17. INSTALLATION OF 0-l?ING/lG. WATER INLET PIPE

become easier.
Caution
Care must be taken not to permit engine oil or other
0410024
Mating marks 15. CONNECTION OF RADIATOR LOWER HOSE

Caution
L
7-28 COOLING - Water Hose and Water Pipe <2.0L DOHC Engine (Non-Turbo)>
<2.0L DOHC Engine (Non-Turbo)>

Post-installgtion Pperation
(FF$efeet; GROUP O-Maintenance
/l--5ia
6 2
/ 5
25-30 Nm
18-22 ft.lbs.
12-1s Nrn
9 - 1 1 ft.lbs.
04A0105
Removal steps
1 Air intake hose 9. Exhaust manifold
2. Condenser fan motor assembly 10. Exhaust manifold gasket
<Vehicles with air conditioner> 11. Exhaust manifold cover(B)
3. Self-locking nut
4. Gasket
6. Exhaust manifold cover (A) NOTE
7. Self-locking nut (1) Reverse the removal procedures to reinstall.
8. Engine hanger (21 m : Non-reusable parts
COOLING - Water Hose and Water Pipe <2.0L DOHC Engine (Non-Turbo)> 7-29
43-55 Nm
04A0117
,-
12. Water hose
13. Water by-pass hose NOTE
14. Connection for heater hose (1) Reverse the removal procedures to reinstall.
+I) l 15. Connection for radiator lower hose (2) 4* : Refer to “Service Points of Removal”.
l 16. Water inlet pipe (3) l 4 : Refer to “Service Points of Installation”
l * 17. O-ring (4) q : Non-reusable parts
NO’IISACZ
Mating marks
04AOO98
INSPECTION N071CAAa2

7-30 COOLING - w ater Hose and Water Piue <2.0L DOHC Ermine (Non-Turbo)>
SERVICE POINTS OF INSTALLATION N071DAJZ
17. INSTALLATION OF O-RING/ 16. WATER INLET PIPE “4

become easier.
Caution
greases to adhere to the O-ring
04ROO24
15. CONNECTION OF RADIATOR LOWER HOSE

Caution
04AOO98
COOLING - Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)> 7-31
WATER HOSE AND WATER PIPE

7-- <2.0L DOHC Engine (Turbo)>
REMOVAL AND INSTALLATION N071A-C
Pre-removal Operation Post-installi ation Operation

eDraining of the Engine Coolant @Filling of the Engine Oil
(Refer to GROUP 7-Service (Refer to GROUP g-Engine
*Draining of the Engine Oil aFilling of the Engine Coolant
(Refer to GROUP g-Engine (Refer to GROUP 7-Service
25-30 Nm 4n-47 ft.lbs.

18-22 ftlbs.
w
35-45 N/m
12-15 Nm 25-33 ft.lbs.
9- 11 ft.lbs.----Q&
Removal steps
1. Condenser fan motor assembly
<Vehicles with air conditioner>
3. Engine oil level gauge guide 2 2 - 2 9 ft.lbs. 29-43 ft.lbs.
4. O-ring
5. Connection for air intake hose 15. Eye bolt
05m154
6. Connection for vacuum hose 16. Gasket
7. Connection for air hose A 17. Connection for water hose
.. 8. Connection for vacuum hose I)+ 18. Connection for water pipe B
9. Heat protector A 19. Self-locking nut
10. Heat protector B 20. Gasket
4* 11. Power steering oil pump 21. Exhaust manifold
12. Oil pump bracket 22. Exhaust manifold gasket
13. Self-locking nut 23. Ring
14. Engine hanger 24. Gasket
7-32 COOLING - Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)>
35-50 Nm
/ 25-36 ft.lbs.
35-50
-- - _ . Nm
__._
25-36 ft.lbs.
25. Oil return pipe
26. Gasket
++ l 27. Turbocharger
28. Eye bolt
29. Gasket
30. Water pipe 6
31. Eye bolt
32. Gasket
33. Water pipe A
22-30 ft.lbs.
30-40 Nm
22-29 ft.lbs. 04A0116
42. Exhaust pipe support bracket

++ 34. Water hose (to turbocharger) 43. Water pipe
35. Water hose l * 44. Water inlet pipe
36. Water by-pass hose l * 45. O-ring
+e l 38. Connection for radiator lower hose
39. Water hose FFTkeverse the removal procedures to reinstall.
40. Water hose (2) a+ : Refer to “Service Points of Removal”.
41. Water hose (3) l + : Refer to “Service Points of Installation”
COOLING - Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)> 7-33
SERVICE POINTS OF REMOVAL NO7lBAC3
11. DISCONNECTION OF POWER STEERING OIL PUMP

Disconnect the oil pump with hoses from the bracket.
NOTE
The removed power steering oil pump should be fastened
(by using rope, etc.) in a position that will not interfere with
the removal/installation of the engine assembly.
27. REMOVAL OF TURBOCHARGER ASSEMBLY
0140552
Remove the turbocharger assembly with the exhaust
fitting, water pipe A, water pipe B and the oil pipe attached
to it.
Mating marks
04A0090
INSPECTION N07lCAAa3

SERVICE POINTS OF INSTALLATION N071DAJ3
45. INSTALLATION OF 0-RING/44. WATER INLET PIPE

become easier.
Caution
r 38. CONNECTION OF RADIATOR LOWER HOSE

Mating marks
Caution
04A0090
7-34 COOLING
Water Hose and Water Pipe <2.0L DOHC Engine (Turbo)>/Engine Coolant Temperature
- Gauge Unit. Engine Coolant Temoerature Sensor and Enoine Coolant Temoerature Switch
34. INSTALLATION OF WATER HOSE

Install the water hose with the longer straight area
positioned on the turbo side.
27. INSTALLATION OF TURBOCHAGER ASSEMBLY
Clean the alignment surfaces shown in the illustration.
Caution
When cleaning, care must be taken so that a piece of
the gasket does not enter the oil passage hole.
05A0026
18. INSTALLATION OF WATER PIPE (B)

Before installing to the water inlet pipe, apply machine oil to
the inner surface of the pipe flare.
05K557
ENGINE COOLANT TEMPERATURE GAUGE UNIT, ENGINE COOLANT

TEMPERATURE SENSOR AND ENGINE COOLANT TEMPERATURE
SWITCH
REMOVAL AND INSTALLATION N070%-
*Draining of the Engine Coolant <2.0L DOHC Engine>
Service.)

< 1.8L Engine>
20-40 10112 Nm
14-29 7 - 9 ft.lbs.
Removal
l + 1. Engine coolant temperature gauge unit
++ 2. Engine coolant temperature sensor
(Engine control)
1 ’
lo-12 Nm *4 3. Engine coolant temperature switch
04AOO99 (Air conditioner)
7-9 ft.lbs.
NOTE
l a : Refer to “Service Points of Installation”.
COOLING
Engine Coolant Temperature Gauge Unit, Engine Coolant
- TemDerature Sensor and Enaine Coolant Temperature Switch 7-35
INSPECTION NomDM3
.--- ENGINE COOLANT TEMPERATURE GAUGE UNIT
Raise the water temperature and measure the resistance if
within the standard value.
Standard value: 104213.5 52 [at 70°C (158OF)l
04GO033
Sensor
ENGINE COOLANT TEMPERATURE SENSOR

(Engine control)
Raise the water temperature and measure the resistance if
within the standard value.
Standard value:
A t 20°C (68°F) 2.45 + 0.24 k&
A t 80°C (176°F) 296f32 8
0400032
ENGINE COOLANT TEMPERATURE SWITCH

(Air conditioner)
(1) Immerse the engine coolant temperature switch in oil and
then heat (by using a gas stove flame or similar method) so
as to increase the oil temperature.
(2) Check to be sure that the engine coolant temperature
switch is switched OFF when the oil temperature reaches
the standard value.
Standard value: 112-l 18°C (234-244°F)
Caution
The oil used above should be engine oil and should be
stirred well while being heated; do not heat more than
necessary.
SERVICE POINTS OF INSTALLATION NO7OEAU
3. ENGINE COOLANT TEMPERATURE SWITCHI2.

ENGINE COOLANT TEMPERATURE SENSOR/l. EN-
GINE COOLANT TEMPERATURE GAUGE UNIT
Apply sealant to threaded portion and tighten.
Specified sealant: MOPAR Part No.4318034 or equiva-
lent
1c0010
NOTES
9-1
ENGINE
CONTENTS NOSAA-
ENGINE <1.8L Engine> .................. 24 CYLINDER HEAD GASKET ........................... 90

CRANKSHAFT, FLYWHEEL AND ENGINE ASSEMBLY ....................................... 81
DRIVE PLATE ................................................ 69 ENGINE MOUNTING ...................................... 77
CYLINDER BLOCK ......................................... 72 ENGINE ROLL STOPPER ............................... 79
CYLINDER HEAD AND VALVE ................... 53 FRONT CASE, OIL PUMP AND
SILENT SHAFT .............................................. 117
CYLINDER HEAD GASKET ........................... 36
OIL PAN AND OIL SCREEN .......................... 87
ENGINE ASSEMBLY ..................................... 31 PISTON AND CONNECTING ROD .............. 127
ENGINE MOUNTING .................................... 28 SERVICE ADJUSTMENT PROCEDURES.. ..... 76
ENGINE ROLL STOPPER ............................. 30 TIMING BELT ................................................ 85
FRONT CASE, OIL PUMP AND TRANSAXLE MOUNTING ............................ 78
SILENT SHAFT .............................................. 58
OIL PAN AND OIL SCREEN ........................ 34 GENERAL INFORMATION ................ 2
PISTON AND CONNECTING ROD .............. 65 SPECIAL TOOLS ............................... 20
ROCKER ARMS AND ROCKER SHAFTS.. .. 51 SPECIFICATIONS ............................... 8
ROCKER ARMS, ROCKER ARM SHAFTS General Specifications ................................ 8
AND CAMSHAFT .......................................... 48 19
Sealants and Adhesives .............................
SERVICE ADJUSTMENT PROCEDURES.. ... 24 Service Specifications ................................. 8
TIMING BELT ................................................ 41 Torque Specifications ................................. 18
TRANSAXLE MOUNTING ............................ 29
TROUBLESHOOTING ........................ 23
ENGINE <2.0L DOHC Engine> . . . . . . 74 Compression Too Low
CAMSHAFTS AND CAMSHAFT Connecting Rod Noise/Main Bearing Noise
OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Excessive Engine Rolling and Vibration
Noisy Valves
CAMSHAFT AND ROCKER ARM . . . . . . . . . . . . . . . . 109
Oil Pressure Drop
CRANKSHAFT, FLYWHEEL AND Oil Pressure Too High
DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Timing Belt Noise
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
CYLINDER HEAD AND VALVE . . . . . . . . . . . . . . . . . . . 112
ENGINE - General Information
GENERAL INFORMATION
SECTIONAL VIEW <1.8L Engine>
3EN0086
SECTIONAL VIEW 
3EN0087
LUBRICATION SYSTEM <1.8L Engine>
r
Oil pressure
A-1
switch
II I
Silent shaft
3LUOOll
SECTIONAL VIEW <2.0L DOHC Engine>
6EN0245
SECTIONAL VIEW <2.0L DOHC Engine>
Lt
6EN0244
ENGINE - General Information 9-7
LUBRICATION SYSTEM <2.0L DOHC Engine>
Roller rocker arm
Lash Can ishaft

adjuster /
Engine coolant
(from thermostat
case)
I Lt
a
Oil filter
63
K
Oil jet
(Turbo only)
Oil pump I y+Oil screen /
6LUOO52
9-8 ENGINE - Specifications
SPECIFICATIONS
B
GENERAL SPECIFICATIONS NDBCA-
Specifications
Items
1.8L Engine 2.0L Engine
Type In-line Single Over Head Camshaft In-line Double Over Head Camshafi
Number of cylinders 4 4
Bore mm (in.) 80.6 (3.17) 85 (3.35)
Stroke mm (in.) 86 (3.39) 88 (3.46)
Compression ratio 9.0 9.0 (Non-Turbo)
7.8 (Turbo)
Firing order l-3-4-2 1-3-4-2
Silent shaft Equipped Equipped
Valve timing
Intake valve
Opens (BTDC) 20” .26” (Non-Turbo)
21’ (Turbo)
Closes (ATDC) 52” 46” (Non-Turbo)
51’ (Turbo)
Exhaust valve
Opens (BBDC) 55” 55”
Closes (ATDC) 17” 9”
Lubrication Pressure feed-full flow filtration Pressure feed-full flow filtration
SERVICE SPECIFICATIONS NOSCB-
-4.8L Engine>
Items Standard Value Limit

Engine adjustments
Engine compression pressure kPa (psi) - Min. 920 (131)
Engine compression pressure difference - Max. 100 (14)
between each cylinder kPa (psi)
Intake manifold vacuum at idle mmHg (in.Hg) 510 (20)
Timing belt “B” tension mm (in.) 5 - 7 (.20-.28)
Cylinder head
Overall height mm (in.) 88.5 (3.484) - 0 . 2 (-.008)*
*Limit must be -0.2
(-.008) combined
with amount of
grinding of cylinder
block gasket surface.
Flatness of gasket surface mm (in.) Less than 0.05 (0019) 0 . 2 (008)
Flatness of manifold mounting surface m m ( i n . ) L e s s t h a n 0 . 1 5 (.0059) 0 . 3 (.012)
ENGINE - Specifications
Valve stem to valve guide clearance mm (in.)

Intake 0.03-0.06 (.0012-.0024) 0 . 1 0 f.004)
Exhaust 0.05-0.09 (.0020-.0035) 0 . 1 5 i.006)
Valve guide
Length mm (in.)
Intake 44 (1.73)
Exhaust 48 (1.89)
Service size mm (in.) 0 . 0 5 (.002), 0 . 2 5 (.OlO),
0.50 i.020) oversize
Valve seat
Width of seat contact mm (in.) 0.9-l .3 (.0354-.0512)
Seat angle 44”-44.5
Valve spring
Free length mm (in.) 4 9 . 2 (1.937) 48.2 (1.898)
Load N (Ibs.) 274.6 (62) at installed height
Out of squarness Less than 2” 4”
Cylinder block
Cylinder bore mm (in.) 80.6 (3.173)
ZIut-of;yundness and taper of cylinder bore Less than 0.01 (.0004)
Cylinder block height mm (in.) 2 8 5 . 2 (11.228)

Flatness of gasket surface mm (in.) Less than 0.05 (.0020) 0 . 1 (.0039)
qight silent shaft

Front journal diameter mm (in.) 38.959-38.975
(1.5338- 1.5344)
Rear journal diameter mm (in.) 35.951-35.967
(1.4154- 1.4160)
Oil clearance mm (in.)
Front journal 0.030-0.061
(.0012-.0024)
Rear journal 0.050-0.091
(.0020- .0036)
-eft silent shaft
Front journal diameter mm (in.) 18.467- 18.480
(.7270- .7276)
(1.4154-1.4160)
Front journal 0.020-0.054 (.0008-.0021)
Rear journal 0.050-0.091 (.0020-.0036)
‘iston
O.D. mm (in.) 8 0 . 6 (3.173)
Clearance (Piston to cylinder) mm (in.) 0.01-0.03 (.0004-.0012)
rIvrs,iz; rework dimension of valve seat hole
Intake 0 . 3 (012) O.S. 43.300-43.325

(1.7047- 1.7057)
0 . 6 (024) O . S . 43.600-43.625
(1.7165-1.7175)
Exhaust 0.3 (.012) O.S. 37.300-37.325
(1.4685- 1.9695)
0 . 6 (024) OS. 37.600-37.625
(1.4803- 1.4813)
Oversize rework of valve guide hole
(both intake and exhaust) mm (in.)
0 . 0 5 (.002) O.S. 13.050- 13.068
(.5138-.5145)
0 . 2 5 (.OlO) O . S . 13.250- 13.268
(.5217-.5224)
0 . 5 0 (.020) O.S. 13.500-13.518
(.5315-.5322)
Camshaft
Cam height mm (in.)
Intake 35.91 (1.4138) 35.41 (1.3941)
Exhaust 35.91 (1.4138) 35.41 (1.3941)
Journal O.D. mm (in.) 33.935-33.950
(1.3360- 1.3366)
Bearing oil clearance mm (in.) 0.05-0.09 (.0020-.0035)
End play mm (in.) 0.1-0.2 (.004-,008)
Rocker arm
I.D. mm (in.) 18.910- 18.928
(.7445- .7452)
Clearance (Rocker arm to shaft) mm (in.) 0.01-0.04 (.0004-.0016) 0 . 1 (004)
Rocker arm shaft

O.D. mm (in.) 18.885- 18.898
(.7435-.7440)
Rocker arm shaft spring
Free length m m (in.)
Intake 5 3 . 3 (2.098)
Exhaust 5 3 . 3 (2.098)
Valve
Valve length mm (in.)
Intake 109.8 (4.323)
Exhaust 108.7 (4.280)
S t e m O.D. mm (in.) 8 (.31)
Face angle 45”-45.5”
Thickness of valve head (Margin) mm (in.)
Intake 1 .o (.039) 0 . 7 (028)
Exhaust 0 . 7 (.028) 0 . 5 (.020)
ENGINE - SDecifications 9-11
ems Standard Value Limit

.-
Ring groove width mm (in.)
No. 1 1.52- 1.54 (.0598-.0606)
No. 2 1.51-l .53 (.0594-.0602)
Oil 4.015-4.045 (.1581-.1593)
Service size mm (in.) 0 . 2 5 (.OlO), 0 . 5 0 (.020),
0 . 7 5 (.030), 1 . 0 0 (.039)
oversize
ston ring
Side clearance mm (in.)
No. 1 0.045-0.085 (.0018-.0033) 0 . 1 2 (.005)
No. 2 0.02-0.06 (.0008-.0024) 0 . 1 (.004)
End gap mm (in.)
No. 1 0.30-0.45 LO1 188.0177) 0 . 8 (.031)
No. 2 0.20-0.35 (.0079-0.138) 0 . 8 i.031)
Oil ring side rail mm (in.) 0.20-0.70 (.0079-.0276) 1.0 (.039)
Service size mm (in.) 0 . 2 5 (.OlO), 0.50 (.020).
0 . 7 5 (.030), 1 . 0 0 LO391
oversize
lnnecting rod
Bend mm (in.) 0.05 or less per 100
(.0020 or less per 3.937)
Twist mm (in.) 0.1 or less per 100
LOO39 or less per 3.937)
Connecting rod bigmKdi,;; crankshaft 0.10-0.25 (.0039-.0098) 0 . 4 (.016)
side clearance
Piston pin press-in load N (Ibs.) 5,000- 15,500 (l ,l OO-3,300)
xrnecting rod bearing

Oil clearance mm (in.) 0.02-0.05 (.0008-.0020) 0 . 1 (.004)
0.75 (.030) undersize
.ankshaft main bearing

Oil clearance mm (in.) 0.02-0.05 (.0008-.0020)
Service size mm (in.) 0 . 2 5 (.OlO), 0 . 5 0 i.0201,
0.75 l.030) undersize
ankshaft
Pin O.D. mm (in.) 45 (1.77)
Journal O.D. mm (in.) 57 (2.24)
Out-of-roundness of journal and pin mm (in.) L e s s t h a n 0.015 (.OOOS)
Taper of journal and pin mm (in.) L e s s t h a n 0.005 (.0002)
tnd play mm (in.) 0.05-0.18 (.0020-.0070) 0 . 4 (.016)
3ms Standard Value Limit
Undersize rework dimension of pin mm (in.)

0 . 2 5 f.010) U . S . 44.735-44.750
(1.7612-1.7618)
0 . 5 0 (.020) U . S . 44.485-44.500
(1.7514-1.7520)
0 . 7 5 (030) U . S . 44.235-44.250
(1.7415-1.7421)
Undersize rework dimension of journal mm (in.)
0 . 2 5 (.OlO) U . S . 56.735-56.750
(2.2337-2.2342)
0 . 5 0 (020) U.S. 56.485-56.500
(2.2238-2.2244)
0 . 7 5 (.030) U.S. 56.235-56.250
(2.2140-2.2146)
wheel
Runout mm (in.) Less than 0.13 (0051)
I pressure at curb idle speed kPa (psi) 80 (11.4) or more

onditions: oil temperature is 75 to 90°C
6 7 t o 194”F)l
1 w-w
Tip clearance mm (in.)
Drive gear 0.06-0.12 (.0024-.0047) 0 . 2 0 i.0079)
Driven gear 0.04-O. 12 (.0016-.0047) 0 . 1 8 (.0071)
Drive gear 0.10-0.16 (.0039-.0063) 0 . 2 0 (.0079)
Driven gear 0.02-0.05 (.0008-.0020) 0 . 1 5 (.0059)
rlief spring
Free length mm (in.) 43.8 (1.724)
L o a d [37N at 8.2 Ibs.] mm (in.) 40.1 (1.5787)
ive belt
For alternator
Deflection mm (in.)
Inspection 9.0- 11.5 (.354-,453)
New belt 7.5-9.0 (.295-.354)
Used belt 1 0 i.394)
Tension N (Ibs.)
Inspection 250-500 (55- 110)
New belt 500-700 (110-154)
Used belt 400 (88)
For air conditioner compressor
Deflection mm (in.)
Inspection Approx. 8 (315)
New belt 5.0-5.5 (.197-.217)
Used belt 6.0-7.0 (.236-.276)
ENGINE - SDecifications
Tension N (Ibs.)
Inspection 250-500 (55-l 10)
New belt 470-570 (104- 126)
Used belt 320-400 (71-88)
For power steering pump
Deflection mm (in.)
Inspection 6.0-9.0 (.236-.354)
Timing belt tension mm (in.) 1 4 (.55)
NOTE
O.D.: Outer Diameter
I.D.: Inner Diameter
OS.: Oversize Diameter
U.S.: Undersize Diameter
<2.0L DOHC Engine>
Engine adjustments
Engine compression pressure kPa (psi) - Min. 960 (137)
(Turbo) - Min. 800 (114)
Engine compression pressure difference - Max. 100 (14)
- between each cylinder kPa (psi)
Intake manifold vacuum at idle m m H g (in.Hg)
<Non-Turbo> 490 (19.3)
<Turbo> 480 (18.9)
Cylinder head
Overall height mm (in.) 132.0 (5.197) - 0 . 2 (-,008)”
*Limit must be -0.2
(- .008) combined
with amount of
grinding of cylinder
block gasket surface.
Flatness of gasket surface mm (in.) ~ less than 0.05 (.0020) 0 . 2 (.008)
Flatness of manifold mounting surface mm (in.) Less than 0.15 (.0059) 0 . 3 (.012)
Oversize rework dimension of valve seat hole
mm (in.)
Intake 0 . 3 (.012) 0,s. 35.300-35.325
(1.3898-1.3907)
0.6 (0.24) 0,s. 35.600-35.625
(1.4016-l .4026)
E x h a u s t 0 . 3 (.012) O S . 33.300-33.325
(1.3110-1.3120)
0 . 6 (.024) 0.S 33.600-33.625
(1.3228- 1.3238)
Items Standard Value Limit ,’
Oversize rework of valve guide hole

(both intake and exhaust) mm (in.)
0 . 0 5 (.002) O.S. 12.050-12.068
(.4744-.4751)
0 . 2 5 (.OlO) O . S . 12.250-12.268
(.4823-.4830)
0 . 5 0 (.020) 0,s. 12.500-12.518
(.4921-.4928)
Camshaft
Cam height mm (in.)
Intake
<Non-Turbo, Turbo-M/T> 35.493 (1.3974) 34.993 (1.3777)
<Turbo-A/T> 35.200 (1.3858) 34.700 (1.3661)
Exhaust
<Non-Turbo, Turbo-A/T> 35.200 (1.3858) 34.700 (1.3661)
<Turbo-MTT> 35.493 (1.3974) 34.993 (1.3777)
Journal O.D. mm (in.) 25.951-25.970
(1.0217-1.0224)
Bearing oil clearance mm (in.) 0.05-0.09 (.0020-.0035)
End play mm (in.) 0.1-0.2 (.004-,008)
Valve
Valve length mm (in.)
Intake 109.5 (4.311)
Exhaust 109.7 (4.319)
Stem O.D. mm (in.)
Intake 6.565-6.580
(.2585-.2591)
Exhaust 6.530-6.550
(.2571-.2579)
Face angle 45"-45.5"
Thickness of valve head (Margin) mm (in.)
Intake 1 . 0 (.040) 0 . 7 (.028)
Exhaust 1 . 5 (.059) 1 . 0 (.040)
Jalve stem to valve guide clearance mm (in.)
Intake 0.02-0.047 (.0008-.0019) 0 . 1 0 (.004)
Exhaust 0.05-0.085 (.0020-.0033) 0 . 1 5 (.006)
Jalve guide
Length mm (in.)
Intake 45.5 (1.791)
Exhaust 50.5 (1.988)
Service size mm (in.) 0 . 0 5 (.002), 0 . 2 5 (.OlO),
0.50 (.020) oversize
/alve s e a t
Width of seat contact mm (in.) 0.9-1.3 (.035-.051)
Seat angle 44"-44.5"
Service size mm (in.) 0 . 3 (.012), 0 . 6 (.024)
oversize
ENGINE - Specifications 9-15
Valve spring
Free length mm (in.) 4 8 . 3 (1.902) 47.3 (1.862)
Load N (Ibs.) 300 (66) at installed height
Out of squarness Less than 1.5” 4”
Cylinder block
Cylinder bore mm (in.) 85.00 (3.3465)
FIu-o$xrndness and taper of cylinder bore Less than 0.01 (0004)
Flatness of gasket surface mm (in.) Less than 0.05 (.0020) 0 . 1 (.0040)
Right silent shaft

Front journal diameter mm (in.) 41.959-41.975
(1.6519-1.6526)
(1.6122-1.6129)
Front journal 0.020-0.061 (.0008-.0024)
Rear journal 0.050-0.091 (.0020-.0036)
Left silent shaft
Front journal diameter mm (in.) 18.467- 18.480
(.7270-.7276)
(1.6126-1.6132)
Front journal 0.020-0.054 (.0008-.0021)
Rear journal 0.042-0.083 (.0017-.0033)
Piston
O.D. mm (in.) 85.00 (3.3465)
CnlIr;;y (Piston to cylinder) ( N o n - T u r b o ) 0.02-0.04 (.0008-.0016)
(Turbo) 0.03-0.05 (.0012-.0020)
Ring groove width mm (in.)
No. 1 1.22-l .24 (.0480-.0488)
No.2 1.52- 1.54 (.0598-.0606)
Oil 3.01-3.03 (.1185-.1193)
0 . 7 5 (.030), 1 .oo i.039)
oversize
‘iston ring
No.1. No.2 0.03-0.07 (.0012-.0028) 0 . 1 (.004)
End gap mm (in.)
No. 1 0.25-0.45 (.0098-.0177) 0 . 8 (.031)
No. 2 0.35-0.50 (.0138-.0197) 0 . 8 (.031)
Oil ring side rail mm (in.) 0.20-0.70 (.0079-.0276) 1 . 0 (.040)
0 . 7 5 (030). 1 . 0 0 i.039)
oversize
Connecting rod
Bend mm (in.) 0.05 or less per 100
(0020 or less per 3.937)
Twist mm (in.) 0.1 or less per 100
(0040 or less per 3.937)
Connecting rod big end to crankshaft 0.10-0.25 (.0040-.0098) 0 . 4 (0157)
side clearance mm (in.)
Piston pin press-in load N (Ibs.) 75,000- 175,000
(1,653-3,858)
Connecting rod bearing

Oil clearance mm (in.) 0.02-0.05 (.0008-.0020) 0 . 1 (.004)
Crankshaft main bearing

Oil clearance mm (in.) 0.02-0.05 (.0008-.0020) 0 . 1 (004)
Crankshaft
Pin O.D. mm (in.) 44.980-44.995
(1.7709-1.7715)
Journal 0.D: mm (in.) 56.980-56.995
(2.2433-2.2439)
Out-of-roundness of journal and pin mm (in.) L e s s t h a n 0.015 (.0006)
Taper of journal and pin mm (in.) L e s s t h a n 0.005 (.0002)
End play mm (in.) 0.05-0.18 (.0020-.0070) 0 . 2 5 LOO981
Flywheel
Runout mm (in.) Less than 0.13 (.0051)
Oil pressure at curb idle speed kPa (psi) 8 0 (11.4) o r m o r e

[Conditions: oil temperature is 75 to 90°C
( 1 6 7 t o 194”F)l
Oil pump
Tip clearance mm (in.)
Drive gear 0.16-0.21 (.0063-.0083) 0 . 2 5 f.0098)
Driven gear 0.13-0.18 (.0051-.0071) 0 . 2 5 t.0098)
Drive gear 0.08-0.14 (.0031-.0055) 0 . 2 5 (.0098)
Driven gear 0.06-0.12 (.0024-.0047) 0 . 2 5 i.0098)
qelief spring
Free length mm (in.) 46.6 (1.835)
L o a d [61N at 13.4 Ibs.] mm (in.) 40.1 (1.579)
ENGINE - Specifications

..--
Drive belt
For alternator
Deflection mm (in.)
Inspection 9.0- 11.5 (.354-.453)
New belt 7.5-9.0 (.295-.354)
Used belt 1 0 i.394)
Tension N (Ibs.)
Inspection 250-500 (55-l 1 0 )
New belt 500-700 (11 o-1 54)
Used belt 400 (88)
For air conditioner compressor
Deflection mm (in.)
Inspection Approx. 8 (.315)
New belt 5.0-5.5 (.197-.217)
Used belt 6.0-7.0 (.236-,276)
Tension N (Ibs.)
Inspection 250-500 (55- 110)
New belt 470-570 (104-126)
Used belt 320-400 (71-88)
For power steering pump
Deflection mm (in.)
Inspection 6.0-9.0 (.236-,354)
Timing belt
Amount;; I;;;j;ction of auto tensioner 1 2 (.47)
rod
Amount;: I;;;jytion of auto tensioner 3 . 8 - 4 . 5 (.15-,181
rod
(distance between the tensioner arm and
auto tensioner body)
Auto tensioner rod retraction wm 2.5-3
NOTE
O.D.: Outer Diameter
I.D.: Inner Diameter
0,s.: Oversize Diameter
U.S.: Undersize Diameter
TORQUE SPECIFICATIONS NO9CG-
Items Nm ftlbs.
Engine mount insulator nut (large) 60-80 43-58

(small) 30-40 22-29
Engine mount bracket nut or bolt 50-65 36-47
Transaxle mount insulator nut 60-80 43-58
Transaxle mount to body 40-50 29-36
Front roll stopper insulator nut 50-65 36-47
Front roll stopper bracket to centermember 40-50 29-36
Rear roll stopper insulator nut 40-50 29-36
Rear roll stopper bracket to centermember 40-50 29-36
Accelerator cable adjusting bolts 4-6 3-4
Fuel high pressure hose to delivery pipe 4-6 3-4
Ground cable to air intake manifold 4-6 3-4
Control wiring harness to air intake plenum 4-6 3-4
Power steering oil pump to bracket 35-45 25-33
Air compressor
conditioner to bracket 23-27 17-20
Exhaust pipe clamp bolt 30-40 22-29
Exhaust pipe to rubber hanger 10-15 7-l 1
Oil pandrain plug 35-45 25-33
Oil pan (bolts) 6-8 4-6
(nuts) 5-7 3.5-5
VVater pump pulley 8-10 6-7
Tensioner pulley bracket (air conditioner compressor) 23-27 17-20
Timing belt front cover 10-12 7-9
Crankshaft sprocket 110-130 80-94
Camshaft sprocket 80-100 58-72
Timing belt “B” tensioner bolt 15-22 11-16
-eft engine support bracket 30-42 22-30
3il pressure switch 8-12 6-9
3il pressure gauge unit 8-12 6-9
Iii filter bracket 15-22 11-16
Iii pump cover 15-18 11-13
qelief plug 40-50 29-36
‘lywheel or drive plate 130-140 94-101
ixhaust pipe
support bracket 30-42 22-30
‘rant roll stopper bracket 55-75 40-54
Iear roll stopper bracket 110-130 80-94
‘rant engine
support bracket 50-70 36-51
:1.8L Engine>
Oil screen 18-25 13-18
Rocker cover 5-7 4-5
Camshaft bearing cap bolt (6 x 20) 20-27 14-20
(8 x 6 5 ) 19-21 14-15
Exhaust pipe to exhaust manifold 30-40 22-29
I n t a k e m a n i f ostay
ld bolt 18-25 13-18
Cylinder head bolt 70-75 51-54
Crankshaft pulley 15-18 11-13
Crankshaft damper pulley 15-18 11-13
ENGINE - Specifications 9-19
Items Nm ft.lbs.
Oil pump sprocket 34-40 26-29

Silent shaft sprocket 34-40 25-29
Timing belt tensioner nut or bolt 22-30 16-22
Timing belt rear cover (upper) IO-12 7-9
(lower) 12-15 9-11
Oil pump driven gear 34-40 25-29
Front case 15-18 11-13
Connecting rod bearing cap 32-35 24-25
Crankshaft bearing cap 50-55 37-39
<2.0L DOHC Engine>
Engine mount bracket to bracket nut or bolt 17-26 12-19
Engine cooler pipe to engine front case 40-45 29-33
Exhaust pipe to exhaust manifold (Turbo) 40-60 29-43
Oil return pipe to oil pan (Turbo) 8-10 6-7
Oil screen nut or bolt 15-22 11-16
Centermember installation bolt 80-l 00 58-72
Oil pipe to engine (Turbo) 14-19 10-14
Rocker cover 2.5-3.5 2-3
Center cover 2.5-3.5 2-3
Heat protector to exhaust manifold 12-15 9-l 1
Exhaust manifold to turbocharger (Turbo) 55-65 40-47
Intake manifold stay bolt 25-30 18-22
-
Cylinder head bolt 90-100 65-72
Crankshaft pulley 20-30 14-22
Oil pump sprocket 50-60 36-43
Silent shaft sprocket 43-49 31-35
Auto tensioner 20-27 14-20
Timing belt tensioner pulley 43-55 31-40
Timing belt idle pulley 34-42 25-30
Timing belt rear cover 10-12 7-9
Oil pump driven gear 34-40 25-29
Front case 20-22 14-16
Engine oil cooler mounting nut 8-12 6-9
Eye bolt (Engine oil cooler side) 30-35 22-25
Engine oil hose mounting bolt 3-5 2-4
Engine oil feed hose assembly to Feed/Return tube assembly 40-50 29-36
Engine oil return hose assembly to Feed/Return tube assembly 40-50 29-36
Feed/Return tube assembly to oil filter bracket 3-5 2-4
Eye bolt (Oil filter bracket side) 40-45 29-33
Crankshaft angle sensor IO-13 7-9
Throttle body stay 15-22 11-16
SEALANTS AND ADHESIVES NOSCE-.
Items Specified sealant

“. _
SemiWrcular MOPAR Part No.4318034
Rocker cover <2.0L
1 ( No.4318034 No.1141~1
1 Oil pan 1 No.MD997110 I
9-20 ENGINE - Special Tools
SPECIAL TOOLS
M D998364 Camshaft oil seal Installation of camshaft oil seal
compressor
Removal and installation of oil pre

ENGINE - Special Tools 9-21
Removal of silent shaft rear bearing
<2.0L DOHC
installer (for engine

with silent shafts)
Crankshaft front oil Installation of crankshaft front oil seal
 seal installer

MD998376
ENGINE - Special Tools
Plug cap wrench Removal and installation of front case cap plug
<2.0L DOHC Engine>
Use with MD998374

<2.0L DOHC Engine>
<2.0L DOHC Engine>
Removal and installation of valve and related

ENGINE - Troubleshooting 9-23

-- Compression too low Cylinder head gasket blown Replace gasket
Piston ring worn or damage Replace rings
Piston or cylinder worn Repair or replace piston and/or cylinder

block
Valve seat worn or damage Repair or replace valve and/or seat ring
Oil pressure drop Engine oil level too low Check engine oil level
Oil pressure switch faulty Replace oil pressure switch
Oil filter clogged Install new filter
Oil pump gears or cover worn Replace gears and/or cover
Thin or diluted engine oil Change engine oil to correct viscosity
Oil relief valve stuck (opened) Repair relief valve
Excessive bearing clearance Replace bearings
Oil pressure too high Oil relief valve stuck (closed) Repair relief valve
Noisy valves Incorrect lash adjuster Bleed air or replace lash adjuster
Thin or diluted engine oil (low oil pressure) Change engine oil
Valve stem or valve guide worn or damage Replace valve and/or guide
Connecting rod noise/ Insufficient oil supply Check engine oil level
main bearing noise
Low oil pressure Refer to “Oil pressure drop”
Thin or diluted engine oil Change engine oil
Excessive bearing clearance Replace bearings
Timing belt noise Incorrect belt tension Adjust belt tension
Excessive engine rolling Loose engine roll stopper (Front, Rear) Retighten
and vibration Loose transaxle mount bracket
Loose engine mount bracket
Loose center member
Broken transaxle mount insulator Replace
Broken engine mount insulator
Broken engine roll stopper insulator
9-24 ENGINE - Service Adjustment Procedures
ENGINE 4.8L Engine>

SERVICE ADJUSTMENT PROCEDURES -
CHECKING COMPRESSION PRESSURE NOSFFAI
(1) Before checking compression, ensure that engine oil, the
starter motor, and battery are all in good condition.
(2) Start the engine and wait until engine coolant temperature
has risen to 85-95°C (185-205°F).
(3) Stop the engine and pull the spark plug cables.
(4) Remove the spark plugs.
(5) Crank the engine to remove any foreign objects in the
cylinders.
Caution
Cover the spark plug holes with shop towel, etc., in
order to keep expelled foreign objects from flying out,
and keep away from the holes. When measuring
compression with water, oil, or fuel having entered the
cylinder through a crack, etc., these will come flying
out of the spark plug hole hot and fast, so be sure to
take the proper precautions.
(6) Set the compression gauge to the spark plug hole.
(7) Holding the throttle valve full open, crank the engine and
measure compression.
Limit: Min. 920 kPa (130 psi) [250-400 rpm]
(8) Perform 6 and 7 above for all the cylinders, ensuring that /I
compression pressure differential for each of the cylinders __
is within the specified limit.
Differential limit: Max. 100 kPa (14 psi)
(9) If a cylinder’s compression or pressure differential exceeds
the limit, add a small amount of oil through the spark plug
hole and repeat steps (6)-(8).
0 If the addition of oil brings compression up, it is possible
that there is poor contact between the piston ring and
cylinder wall.
@ If not compression does not come up, valve seizure,
poor valve seating, or a compression leak from the
gasket are all possible.
/y
-
ENGINE <1.8L Engine> - Service Adjustment Procedures 9-25
MANIFOLD VACUUM INSPECTION
(1) Before inspection and adjustment, put the vehicle in=
following state.
l Engine coolant temperature: 85-95°C (185-205°F)
l Lights, electric, cooling fan, and accessories: OFF
l Transaxle: Neutral (N or P for vehicles with an automa-
tic transaxle)
l Steering wheel: Neutral position
(2) Check that the idling revolution speed is normal.

(3) Remove the PCV hose from the PCV valve and attach a
vacuum gauge.
(4) Check that the negative pressure at the intake manifold
during idle revolution is normal.
Standard value: 510 mmHg (20 in.Hg)
(5) If outside the standard value, isolate the cause by referring
to the following table and repair the fault.
Symptom Cause Remedy
l The vacuum gauge reading is less than l Ignition timing is retarded. l Adjust the ignition timing.
- standard value, but the pointer is
stable.
l The vacuum gauge pointer swings l Air mixture concentration too l Check ECI-MULTI system.
slowly. rich.
l The vacuum gauge pointer drops irre- l Air mixture concentration too l Check ECI-MULTI system.
gularly. lean.
l The vacuum gauge pointer drops inter- 0 Incomplete close contact of in- l Check and repair the valve.
mittently to 30 to 160 mmHg (1.2 to take exhaust valve seat.
6.3 in.Hg).
l The vacuum gauge pointer drops sud- l Broken cylinder head gasket l Replace cylinder head gasket.
denly from the normal reading to 250
rronnrt$,(9.8 rn.Hg), then returns to
9-26 ENGINE <1.8L Engine> - Service Adjustment Procedures
TIMING BELT TENSION ADJUSTMENT NOSFGBC
There are two access holes provided in the timing belt front
lower cover. The two access holes can be used to readjust the
tension of the timing belt, by following the procedures
described below, without the necessity of removing the timing
belt front lower cover. Note, however, that timing belt “B”,
which drives the right silent shaft, cannot be adjusted unless
the cover is removed.
(1) Turn the steering wheel all the way to the left.
(2) Remove the left side undercover panel.
NOTE
This work is done so that the crankshaft can be turned.
(3) Place a piece of wood against the engine oil pan and jack
(4) :tmove the engine mounting bracket.

(5) Remove the timging belt front upper cover.
(6) Remove the four spark plugs.
(7) Turn the crankshaft clockwise and check the timing belt
condition.
OlAOOBl
Timing mark (8) Turn the crankshaft clockwise and align the timing marks.
(on upper under cover)
Timing mark
(on camshaft sprocket)
OlR0153
(9) Remove the air conditioner drive belt and the alternator
drive belt.
(10)Remove the access cover (two places). There are easily
removed by inserting a screwdriver into the slots indicated
by the raised arrows in the timing belt cover and twisting.
(1l)lnser-t a socket wrench [a 14 mm (.55 in.) box wrench]
cover through the hole in the access cover and loosen the timing
belt tension bolt and nut.
Caution
i‘I!
The timing belt tension bolt and nut need only be
OlA0082
loosened 180”-200”. Any further loosening might re-
sult in their falling off inside the timing belt cover.
01 A0083
ENGINE <1.8L Engine> - Service Adjustment Procedures 9-27
(12)Turn the crankshaft clockwise by two teeth of the camshaft
Timing mark sprocket.
(on upper under cover)
Timing belt
Timing mark A
(on camshaft
sprocket) OlR0154
(13)First tighten the timing belt tensioner installation bolt (on

the lower side), and then tighten the tensioner spacer
(upper side).
Caution
Be sure to tighten the bolt (lower side) first. If the
tensioner spacer of pivot side is tightened first, the
tensioner will rotate with it and belt tension may
become loose.
3EN076
(14)lnstall the access cover. The access cover may be easily

installed by passing the hooks between the guides and
sliding it in.
(15)lnstall the air conditioner drive belt and alternator drive belt
and adjust the slack.
I.
(16)lnstalI the timing belt front upper cover.

(17)lnstall the engine mounting bracket.
(18)lnstalI the spark plugs.
(19)lnstall the left side undercover panel.
3EN07;
-
LASH ADJUSTERS CHECK NO9FEABaO
If an abnormal noise is heard from the lash adjusters check as

follows.
(I) After warming up the engine, stop it.
(2) While installed to the cylinder head, press the part of rocker
feel very hard if the lash adjuster condition is normal.

(3) If, when pressed, it easily descends all the way downward,
(4) If there.is a spongy feeling when pressed, air is probably
cause is probably an insufficient amount of engine oil, or

damage to the oil screen and/or screen gasket.
(adding oil or repair), warm up the engine and drive at low

speed for a short time. Then, after stopping the engine and
this procedure a few times to bleed out the air from the oil.
9-28 ENGINE <1.8L Engine> - Engine Mounting
ENGINE MOUNTING NOB8A-A
IEMOVAL AND INSTALLATION
Post-installation Operation 50-65 Nm

*Lower the Engine 36-47 ft.lbs.
30-40 Nm
22-26 ft.lbs.
Removal steps
1. Pressure hose (power steering)
2. Engine mount bracket and body
connection bolt NOTE
3. Engine mount bracket (1) Reverse the removal procedures to reinstall.
e+ 4. Mounting stopper (2) +* : Refer to “Service Points of Installation”
INSPECTION NOOQCANO
l Check each insulator for cracks or damage.

l Check each bracket for deformation or damage.
Mounting SERVICE POINTS OF INSTALLATION

4. INSTALLATION OF MOUNTING STOPPER
Install the mounting stopper of the engine mount bracket
so that the arrow faces the center part of the engine.
Arrow
OiA0004
ENGINE <1.8L Engine> - Transaxle Mounting
TRANSAXLE MOUNTING NOSGE-A

*Raise and Suspend the Transaxle to aLower the Transaxle
the Extent Force is not applied to l installation of the Air Cleaner
the Transaxle Mount (Refer to GROUP II-Air Cleaner.)
@Removal of the Air Cleaner
(Refer to GROUP 11-Air Cleaner.)
<M/T>
40-50 Nm
29-36 ft.lbs.
W-60 Nm
/
43-56 ft.lbs.
Transaxle
mount
bracket
<A/T>
40-50 Nm 3
29-36 ft.lbs.
60-80 Nm
43-58 ft.lbs.
Removal steps
1. Transaxle mount bracket and transaxle
connection bolt
2. Caps
3. Transaxle mount bracket installation bolts
4. Transaxle mount bracket
5. Mounting stopper
NOTE
Reverse the removal procedures to reinstall.
INSPECTION NOOGCAHl

.I
9-30 ENGINE - Engine Roll Stopper
ENGINE ROLL STOPPER

40-50 Nm
29-36 ft.lbs.
l Raise and Suspend the Engine to the
*Lower the Engine
40-50 Nm
29-36 ft.lbs.
\ /*
50-65 Nm*
36-47 ft.lbs.*
01A0012
Front roll stopper bracket removal steps

1. Front roll stopper bracket and engine
connection bolt
2. Front roll stopper bracket installation bolts
l + 3. Front roll stopper bracket NOTE
(1)Reverse the removal procedures to reinstall.,,
Rear roll stopper bracket removal steps I;/ I)+ : Refer to Service Points of Installation
Non-reusable parts
4. Rear roll stopper bracket and engine (4) P or tightening locations indicated by the * symbol, first
connection bolt tighten temporarily, and then make the final tightening
5. Rear roll stopper bracket installation bolts with the entire weight of the engine applied to the
6. Rear roll stopper bracket vehicle body.
INSPECTION NosGcAH2
Forward l Check each insulator for cracks or damage.

SERVICE POINTS OF INSTALLATION NOSGJASl
3. INSTALLATION OF FRONT ROLL STOPPER BRACKET

Round h&
(1) Install the front roll stopper bracket so that the part
where the round hole is made is facing the forward of
the vehicle.
Front roll (2) After temporarily tightening the front roll stopper
bracket bracket, tighten so that, in the unladen vehicle condi-
tion, the distance from the center hole of the insulator
to the lower edge of the bracket is the specified
distance.
51.7-57 .7 mn
12.0-2.3 in.)
ENGINE <1.8L Engine> - Engine Assembly 9-31
ENGINE ASSEMBLY N69SA-A
. REMOVAL AND INSTALLATION

@Eliminating Fuel Pressure in Fuel Line
Procedures.)
@Removal of Engine Hood “7
eDraining of Engine Coolant
(Refer to GROUP O-Maintenance Service.)
l Removal of the Transaxle Assembly
(Refer to GROUP 21 -Transaxle Assembly.)
*Removal of the Radiator
(Refer to GROUP 7-Radiator.)
@Installation of the Radiator
l Installation of the Transaxle Assembly
@Refilling of Engine Coolant
l Installation of Engine Hood
/ 1
6
OlA0566
4-6 Nm
3 - 4 ft.lbs.
\
16
4 - 6 Nm
/ 16 io 4 - 6 1 Nm \ 19
3 - 4 ft.lbs. 17 3 - 4 ft.lbs. OlA0643
Removal steps
l + 1. Connection for accelerator cable or
throttle cable
2. Connection for accelerator cable 12. Connection for ISC
(Auto-cruise control) 13. Connection for TPS
3. Connection for fuel high pressure hose 14. Connection for MPS
4. O-ring 15. Connection for fuel injectors
5. Connection for heater hoses 16. Connection for EGR temperature sensor
6. Connection for vacuum hoses 17. Connection for distributor
7. Connection for fuel return hose 18. Connection for CRC filter
8. Connection for brake booster vacuum 19. Connection for ground cable
hose 20. Control wiring harness
9. Connection for oxygen sensor
10. Connection for engine coolant NOTE
temperature gauge unit (1) Reverse the removal procedures to reinstall.
11. Connection for engine coolant (2) l + : Refer to “Service Points of Installation”.
temperature sensor (3) m : Non-reusable parts
9-32 ENGINE <1.8L Engine> - Engine Assembly
35-45 Nm
25-33 ft.lbs.
25 31
\ 5$M35 Nm
36-47 ft.lbs.
OlAO564
29-36 ft.lbs.
\
60-80 Nm
43-58 ft.lbs.
OlAO563
3&40 Nm
22-29 ft.lbs.
Removal steps 30. Self-locking nut
21. zztTtion for power steering oil pump 4e +4 31. Engine assembly
Connection for alternator ITE

Connection for oil pressure switch Reverse the removal procedures to reinstall.
+e l + 24. Power steering oil pump l * : Refer to “Service Points of Removal”.
l * : Refer to “Service Points of Installation”.
*I) l 4 25. Air conditioner compressor ; Non-reusable parts
26. palffz,cklng nuts P or ttghtening locations indicated by the * symbol, firs1 t
27. tighten temporarily, and then make the final tightening
28. Clamp of pressure hose (Power steel with the entire weight of the engine applied to the
4+ 29. Engine mount bracket vehicle body.
SERVICE POINTS OF REMOVAL Nogs6SC
24. REMOVAL OF POWER STEERING OIL PUMP

Remove the oil pump (with the hose attached).
NOTE
Suspend the removed oil pump (by using wire or similar
material) at a place where no damage will be caused during
removal/installation of the engine assembly.
ENGINE <1.8L Engine> - Engine Assemblv 9-33
25. REMOVAL OF AIR CONDITIONER COMPRESSOR
c Disconnect the connection of the air conditioner compress-
or, and then remove the compressor (with the hose
attached) from the compressor bracket.
NOTE
Suspend the removed air conditioner compressor (by using
wire or similar material) at a place where no damage will be
caused during removal/installation of the engine assembly.
OlAO582
!
(1) Attach wire or similar material to the engine hook, and
then suspend (to the extent that there is no slackness
of the wire) by using a chain block or similar arrange-
ment.
31. REMOVAL OF ENGINE ASSEMBLY

(1) Check to be sure that all cables, hoses, harness
connectors, etc. are disconnected from the engine.
(2) Lift the chain block slowly to remove the engine
assembly upward from the engine compartment.
SERVICE POINTS OF INSTALLATION NOSSDAT
31. INSTALLATION OF ENGINE ASSEMBLY

install the engine assembly. When doing so, check careful-
ly to be sure that all pipes and hoses are connected, and
that none are twisted, damaged, etc.
25. INSTALLATION OF AIR CONDITIONER COMPRESSOR
24. INSTALLATION OF POWER STEERING OIL PUMP
1. ADJUSTMENT OF ACCELERATOR CABLE OR THROT-
TLE CABLE
9-34 ENGINE <1.8L Engine> - Oil Pan and Oil Screen
OIL PAN AND OIL SCREEN

c/(Refer to GROUP O-Maintenance
30-40 Nm
22-29 ftlbs.
Removal steps
1. Drain plug
2. Connection for exhaust pipe
3. Gasket
** l + 4. Oil pan
5. Oil screen
6. Gasket
NOTE
(2) +e : Refer to “Service Points of Removal”. lo-15 Nm
(3) l + : Refer to “Service Points of Installation”. 7 - 1 1 ftlbs.
(4) m : Non-reusable parts 35-45 Nm OlAO546
25-33 ftlbs.
-
,,Mq998727_ /1 SERVICE POINTS OF REMOVAL NOSHBAFaO
4. REMOVAL OF OIL PAN

(1) Remove the oil pan mounting bolts.
(2) Tap the special tool in between the cylinder block and
the oil pan.
Caution
Do not use a screwdriver, a chisel or a similar tool
when removing the oil pan.
(3) Remove the oil pan by placing a brass bar at the corner
of the special tool and then tapping with a hammer.
INSPECTION NOHCACO
l Check the oil pan for damage and cracks. Replace if faulty.
l Check the oil screen for clogging; damage and cracks.
Replace if faulty.
ENGINE - Oil Pan and Oil Screen 9-35
SERVICE POINTS OF INSTALLATION IYW~DU)
4. INSTALLATION OF OIL PAN
(1) Use a wire brush or other tool to scrape clean all gasket
surfaces of the cylinder block and oil pan so that all
loose material is removed.
(2) Gasket surfaces must be free of oil and dirt.
(3) Apply the specified sealant around the gasket surface

of oil pan as specified in illustration.
Specified sealant: MITSUBISHI GENUINE PART
No. MD9971 10 or equivalent
NOTE
The sealant should be applied in a continuous bead
approximately 4 mm (.I6 in.) in diameter.
(4) Assemble oil pan to cylinder block within 15 minutes

after applying the sealant.
Caution
After installing the oil pan, wait at least 30 minutes
before starting the engine.
9-36 ENGINE <l.$L Engine> - Cylinder Head Gasket
CYLINDER HEAD GASKET NWJA-A
4-6 Nm
REMOVAL AND INSTALLATION 7 3 - 4 ft.lbs.
l Eliminating Fuel Pressure in Fuel
Line
(Refer to GROUP 14-Service Ad-
justment Procedures.) 8
*Draining of En ine Coolant
(Refer to GRO 9P -/-Service Adjust-
ment Procedures.)
~~~~~~~n
(Refer to GROUP 7-Service Adjust-
?*
29 ?i
OlAO556
30-46 Nm
22-29 ft.lbs.
60-80 ium
43-58 ftlbs.
1 \4-6 Nm
3 - 4 ftlbs.
25 iy 24 \ \
3 - 4 ftlbs. / 22 27 26 QlAO644
17. Connection for engine coolant

Removal steps temperature gauge unit
1. Air intake hose 18. Connection for engine coolant
2. Connection for breather hose temperature sensor
I)4 3. Connection for accelerator cable or 19. Connection for ISC
throttle cable 20. Connection for TPS
4. Connection for accelerator cable 21. Connection for MPS
(Auto-cruise control) 22. Connection for distributor
l + 5. Connection for fuel high pressure hose 23. Connection for injector
6. O-ring 24. Connection for EGR temperature sensor
+e W 7. Connection for radiator upper hose (California vehicles only)
8. Connection for water hose 25. Connection for CRC filter
9. Connection for water by-pass hose 26. Connection for ground cable
10. Connection for heater hose 27. Control wiring harness
11. Connection for vacuum hose 28. Clamp for pressure hose (Power steering)
12. Connection for PCV hose 29. Engine mounting bracket
13. Connection for spark plug cable NOTE
14. Connection for fuel return hose (I) Reverse the removal procedures to reinstall.
15. Connection for brake booster vacuum (2) Ce : Refer to “Service Points of Removal”.
hose (3) ++ : Refer to “Service Points of Installation”.
16. Connection for oxygen sensor (4) m : Non-reusable parts
ENGINE - Cylinder Head Gasket 9-37
5 - 7 Nm
70-75 Nm
51-54 ftlbs.
I
80-100 Nm
58-72 ftlbs.
- 1 2 Nm
.9 ft.lbs.
ii-29 ft.lbs.
18-25 hm
13-18 ft.lbs.
OlAoO92
30. Rocker cover
M 31. Semi-circular packing
32. Timing belt front upper cover
4* 33. Camshaft sprocket
34. Timing belt rear upper cover
NOTE
35. Self-locking nuts (1) Reverse the removal procedures to reinstall.
36. Gasket (2) *I) : Refer to “Service Points of Removal”.
+* l + 37. Cylinder head assembly (3) l 4 : Refer to “Service Points of Installation”.
l + 38. Cylinder head gasket (4) m : Non-reusable parts
9-38 ENGINE <1.8L Engine> - Cylinder Head Gasket
SERVICE POINTS OF REMOVAL NWJSAO
7. REMOVAL OF RADIATOR UPPER HOSE ,z

Make mating marks on the radiator hose and hose clamp, b-
and then disconnect the radiator hose.
29. REMOVAL OF ENGINE MOUNTING BRACKET

(1) Jack up the vehicle after placing a wooden block
between the jack and the engine’s oil pan.
Caution
Jack up carefully, so as not to apply an excessive
load to the various parts.
04UOO27
Timing mark 33. REMOVAL OF CAMSHAFT SPROCKET

(1) Turn the crankshaft clockwise and align the timing
mark.
Caution rz
The crankshaft must always be rotated in the -’
clockwise only.
\
Timing mark
OlR0153
(2) Remove the camshaft sprocket (with the timing belt

attached), and place on the timing belt front lower
cover.
Caution
After removing the camshaft sprocket, be sure not
to rotate the crankshaft.
R
ENGlNE <1.8L Engine> - Cylinder Head Gasket 9-39
37. REMOVAL OF CYLINDER HEAD ASSEMBLY
TW-1 OB
(1) Using the special tool, remove cylinder head bolts in
sequence shown in figure.
(2) Remove the cylinder head assembly.
Front of engine r,
Intake side
Exhaust side
01R0390
SERVICE POINTS OF INSTALLATION NO9JDDHs
38. INSTALLATION OF CYLINDER HEAD GASKET

(1) Use a scraper to remove the cylinder head gasket from
the cylinder block.
Caution
Take care that no foreign material gets into the
cylinder, or into coolant or oil passages.
I
identification (2) Clean the cylinder block and head surfaces that are in
mark contact with the gasket.
(3) Lay the cylinder head gasket on cylider block with the
identification mark at front top.
Caution
Do not apply sealant to cylinder head gasket.
6EN025
37. INSTALLATION OF CYLINDER HEAD ASSEMBLY

(1) Use a scraper to remove the cylinder head gasket from
the cylinder head assembly.
Caution
coolant or oil passages.
Olm415
ENGINE <1.8L Engine> - Cylinder Head Gasket
(2) Using the special tool, tighten the bolts in the order
shown in two or three steps.
a-2
OlAOlO:
Front of engine I,
Intake side
Exhaust side
01R0390
4pply sealant 1 31. APPLICATION OF SEALANT TO SEMI-CIRCULAR PACK-

ING
Apply a coating of the specified sealant to the semi-circular
packing and the cylinder head top surfaces. /L
Specified sealant: MOPAR Part No.4318034 or equiva- _ ‘-
lent
7. INSTALLATION OF RADIATOR UPPER HOSE

Align the mating marks (of the radiator hose and hose
clamp), and then, while applying force in the direction of
Mating marks .,
the arrow in the illustration, set the hose clamp to the
trace marks (on the hose) remaining from the prior
connection.
Caution
Be sure to install the hose clamp at the trace marks (on
the hose) remaining from the prior connection.
5. CONNECTION OF FUEL HIGH PRESSURE HOSE

Delivery pipe When connecting the fuel high-pressure hose to the
delivery pipe, apply a coating of gasoline to the hose union,
and insert so that the O-ring is not damaged.
3. INSTALLATION OF ACCELERATOR CABLE OR THROT- +
TLE CABLE CONNECTION
iigh
3ressure
lose O-ring
03Aoo79
ENGINE <1.8L Engine> - Timing Belt
TIMING BELT
- REMOVAL AND INSTALLATION ,
50-65 Nm @Removal of Under Cover
36-47 ft.lbs.
\ 1 6 - 2 2 ftlbs. \
I
lo-12 Nm
7 - 9 ft.lbs.
12-15 Nm
9- 11 ft.lbs.
28
15-22 Nm
11-16 ft.lbs.
3hO Nm
26-29 ft.lbs.
110-130 Nm
(( \\ _ 60-94 ftlbs.
15-16 Nm -23-27 Nm OlAO555
11-13 ft.lbs. 17-20 ft.lbs.

Removal steps
l 4 20. Timing belt tensioner
1. Clamp for pressure hose (power steering) I)+ 21. Tensioner spacer
4* 2. Engine mount bracket l 22. Tensioner spring
I)* 3. Drive belt (power steering) 23. Camshaft sprocket
4. Tensioner pulley bracket 4* 24. Oil pump sprocket
H 5. Drive belt (air conditioner) 25. Crankshaft sprocket
l + 6. Drive belt (alternator) l 26. Flange
7. Water pump pulley (power steering) 27. Timing belt tensioner “B”
8. Water pump pulley ~~ l 28. Timing belt “B”
9. Damper pulley l 4 Adjustment of timing belt “B” tension
10. Adapter 29. Right silent shaft sprocket
11. Crankshaft pulley l * 30. Spacer
I)4 12. Timing belt front upper cover ~~ 31. Crankshaft sprocket “B”
13. Gasket 32. Key
l 14. Timing belt front lower cover 33. Left engine support bracket
15. Gasket 34. Timing belt rear upper cover
16. Access cover 35. Timing belt rear lower cover
17. Crankshaft sprocket bolt
18. Special washer NOTE
Adjustment of timing belt tensioner (1) Reverse the removal procedures to reinstall.
l * :: 19. Timing belt (2) 4* : Refer to “Service Points of Removal”.
g-42 ENGINE <1.8L Engine> - Timing Belt
SERVICE POINTS OF REMOVAL NO9KBBCa
2. REMOVAL OF ENGINE MOUNT BRACKET a

(1) Jack up the vehicle after placing a wooden block :.
between the jack and the engine’s oil pan.
Caution
Jack up carefully so as not to apply an excessive
load to the various parts.
r- 04UOO27
19. REMOVAL OF TIMING BELT

,Timing mark
marks.
Caution
The crankshaft must always be turned clockwise.
Timing‘mark
(2) Make a mark on the back of the timing belt indicating

the direction of rotation so it may be reassembled in the
same direction if it is to be reused.
lEN0017
(3) Loosen the bolt and tension spacer of the timing belt
tensioner.
c
(4) Move the timing belt tensioner to the water pump side
and loosely tighten the bolt so that the tensioner
li
doesn’t return; then remove the timing belt.
OlA0550
NOTE
If the timing belt is to be re-used, use chalk to’mark (on
its flat side) an arrow indicating the clockwise direction.
Caution
1. As water or oil on the belt can seriously reduce
its usable life, ensure that the timing belt,
sprocket, and tensioner stay clean and dry while ic
removed, and never wash them. Parts that have *
become too dirty should be replaced.
2. When any of the parts are oily, check to see
whether there are any oil leaks in any of the oil
seals or the camshaft oil seal on the front of the
engine.
ENGINE <1.8L Engine> - Timing Belt 9-43
24. REMOVAL OF OIL PUMP SPROCKET
(1) Remove the plug on the side of the cylinder block.
(2) Insert a Phillips screwdriver [shank diameter 8 mm (.31
in.)] to block the left silent shaft.
(3) Remove the oil pump sprocket nut.
(4) Remove the oil pump sprocket.
28. REMOVAL OF TIMING BELT “B”

Make a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
Caution
Water or oil on the belt shorten its life drastically, so
the removed timing belt, sprocket, and tensioner must
be free from oil and water. These parts should not be
washed. Replace parts if seriously contaminated.
If there is oil or water on each part check the front case
oil seals, camshaft oil seal and water pump for leaks.
- INSPECTION
TIMING BELTS
NOSKCAD
. The timing belts must be checked closely. Should the following

defects be evident, replace the belt with a new one.
:4iJ
(1) Hardened back surface rubber
,0000 8
Glossy, non-elastic, and so hard that no mark is produced
even when scratched by a fingernail.
7EN206
(2) Cracked back surface rubber.

(3) Cracked or separated canvas.
(4) Cracked tooth bottom.
Crack (5) Cracked side.
7EN207
(6) Abnormal wear on side.

NOTE
Normal belt should have clear-cut sides as if cut by a sharp
knife.
Abnormal wear
(fluffy canvas fiber) 7EN2013
9-44 ENGINE <1.8L Engine> - Timing Belt
(7) Abnormal wear on teeth.

Initial stage:
Rubber Canvas on load side tooth flank worn (Fluffy canvas a
exposed
fibers, rubber gone and color changed to white, and -
unclear canvas texture)
Tooth missing and Final stage:
Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
(8) Missing tooth.
TENSIONER PULLEY
Turn the pulleys to check for possible binding, excessive play,
and unusual noise. Replace the pulley if any of these defects
” is
evident.
1 EN0002
Crankshaft SERVICE POINTS OF INSTALLATION

sprocket “6 31. INSTALLATlON OF CRANKSHAFT SPROCKET “6”
Install the crankshaft sprocket “B” as shown while paying ~,
attention to its direction.
‘d
Crankshaft 6EN304
J
30. INSTALLATION OF SPACER

Spacer
(1) Apply a thin coat of engine oil to the outer circumfer-
ence of the spacer.
(2) Install the spacer with the chamfered end facing the oil
seal.
NOTE
If the spacer is installed adversely, the oil seal may be
damaged, resulting in the oil leaks.
Chamfered
6EN009
28. INSTALLATION OF TIMING BELT “B”

(1) Ensure that crankshaft sprocket “B” timing mark and
the silent shaft sprocket timing mark are aligned.
(2) Fit timing belt “B” over crankshaft sprocket “B” and
the silent shaft sprocket. Ensure that there is no slack in +
the belt. a.
TiGGrn
mark
Crankshaft \v
sprocket “B”
. ADJUSTMENT OF TIMING BELT “B” TENSION
(1) Temporarily fix the timing belt “B” tensioner such that
the center of the tensioner pulley is to the left and
above the center of the installation bolt, and temporarily
attach the tensioner pulley so that the flange is toward
the front of the engine.
J
(2) Holding the timing belt “B” tensioner up with your
finger in the direction of the arrow, place pressure on
the timing belt so that the tension side of the belt is
taut. Now tighten the bolt to fix the tensioner.
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension on the belt.
(3) To ensure that the tension is correct, depress the belt

(point A) with a finger. If not, adjust.
Standard value: 5-7 mm (.20-.28 in.)
I
01R0409
Crankshaft 26. INSTALLATION OF FLANGE

sprocket )IB”
Install the flange in correct direction as shown.
I Crankshafi
sprocket
Crankshaft
6EN272
1
22. INSTALLATION OF TENSIONER SPRING/21. TEN-
SIONER SPACERI20. TIMING BELT TENSIONER
(1) Install the tensioner spring, tensioner spacer and timing
belt tensioner.
(2) Place the upper end of the tensioner spring against the
water pump body.
9-46 ENGINE <1.8L Engine> - Timing Belt
(3) Move tensioner fully toward water pump and tempor-

arily secure tensioner.
19. INSTALLATION OF TIMING BELT

(1) Ensure that the timing marks of the camshaft sprocket,
the crankshaft sprocket, and the oil pump sprocket are
all aligned.
Timing mark
Q1hQS4.9
(2) When aligning the timing mark of the oil pump

sprocket, remove the plug of the cylinder block; then
insert the shaft of a cross-tip (+) screwdriver with a
shaft diameter of 8 mm (.31 in.) into the plug hole and
check to be sure that the screwdriver’s shaft can be
inserted at least 60 mm (2.36 in.). Do not remove the
screwdriver until the timing belt is completely attached.
If the screwdriver’s shaft can be inserted only to a
depth of about 20 to 25 mm (.79 to .98 in.) because it
contacts the silent shaft, turn the sprocket by one
3EN005 rotation and align the timing mark once again; then
check again to be sure that the screwdriver’s shaft can
be inserted at least 60 mm (2.36 in.).
(3) Install timing belt. While making sure that tension side
of belt is not slackened, install timing belt onto
crankshaft sprocket, oil pump sprocket and camshaft
sprocket in that order.
Caution
If the timing belt is reused, install so that the arrow
marked on it at the time of removal is pointing in
the clockwise direction.
OlA0549
. ADJUSTMENT OF TIMING BELT TENSION

(1) Loosen tensioner mounting nut. By so doing, tensioner
c will be moved by spring and will apply tension to belt.
(2) Recheck to be sure that each sprocket’s timing mark is
correct.
::
OlAO550
-
(3) Turn the crankshaft clockwise by two teeth of the
Timing mark camshaft sprocket.
Caution
As the purpose of this procedure is to apply the
proper amount of tension on the timing belt, be
sure not to rotate the crankshaft counterclockwise
or place pressure on the belt to check the amount of
tension.
(4) Apply force on tensioner toward turning direction, (in

the direction of the arrow) such that no portion of the
belt raises out in portion A, place the belt on the
camshaft sprocket such that the belt sprocket teeth are
Nut fully engaged.
(5) Tighten the tensioner installation bolt and tensioner
spacer in that order.
Caution
If the tensioner spacer is tightened first, the ten-
sioner will rotate with it and belt tension be thrown
out of adjustment. Always tighten the bolt first.
(6) Check to see that the clearance between the outside of
the belt and the cover are within the standard value by
grasping the tension side (between the camshaft
sprocket and oil pump sprocket) of the centre part of
the timing belt between the thumb and index finger.
Standard value: 12 mm (.40 in.)
;olt diameter x length 14. INSTALLATION OF TIMING BELT FRONT LOWER

im (in.) COVER/12. TIMING BELT FRONT UPPER COVER
Note that the timing belt lower and upper cover attaching
6x50 bolts differ in size from one place to another.
(.23 x 1.97)
6 x 38
(.23 x 1.50)
6. TENSION ADJUSTMENT OF THE ALTERNATOR DRIVE

BELT
5. TENSION ADJUSTMENT OF THE AIR CONDITIONER
COMPRESSOR DRIVE BELT
Refer to GROUP 24- Service Adjustment Procedures.
3. DEFLECTION ADJUSTMENT OF POWER STEERING OIL
PUMP DRIVE BELT
9-48 ENGINE <1.8L Engine> - Rocker Arms, Rocker Arm Shafts and Camshaft
ROCKER ARMS, ROCKER ARM SHAFTS AND CAMSHAFT UOSLE-A
5-7 Nm
4-5 ft.lbr
8
a - - - - 8
19-21 Nm
20-27 Nm
Disassembly steps
1. Camshaft sprocket
2. Breather hose SO-100 Nm
3. P.C.V. hose 58-72 ft.lbs.
4. P.C.V. valve
5. Oil seal
;. Fbz;~; cover
l + 8: Semi-circular packing
+e I)+ 9. Rocker arm and shaft assembly
10. Camshaft
l * 11. Oil seal
NOTE
(1) Reverse the disassembly procedures to reassemble.
(3) W : Refer to “Service Points of Reassembly”.
ENGINE <1.8L Ennine> - Rocker Arms, Rocker Arm Shafts and Camshaft&49
MD998443 1 SERVICE POINTS OF DISASSEMBLY

9. REMOVAL OF ROCKER ARM AND SHAFT ASSEMBLY
NWLFM.
Before removing the rocker arm and shaft assembly, use

the special tool to ensure that the lash adjuster doesn’t fall
out.
Caution
Put the rocker arms and lash adjusters in order in
cylinder No. separated places with clear distinction
between the intake and exhaust ones to prevent
6EN245 confusion.
Fuel pump
I
INSPECTION NOBLCDDI
CAMSHAFT
(1) Visually check the camshaft journal surfaces and replace if
damage or seizure is evident.
If the journal is seized, check the cylinder head for possible
damage. Check also for clogged oil holes in the cylinder
head.
3EN287
r (2) Check cams for excessive wear and damage and replace if
defects are evident. Measure the cam height and replace if
the limit is not reached.
0
Standard value: 35.91 mm (1.4138 in.)
Cam Limit: 35.41 mm (1.3941 in.)
height
6EN0184
SERVICE POINTS OF INSTALLATION NOSLQACa

(1) Apply engine oil to oil seal lip.
(2) Using the special tool, drive the camshaft oil seal into
the cylinder head.
hl,
3EN153
, Oil seal
MD998364
DEN632
S-50 ENGINE 4.8L Engine> - Rocker Arms, Rocker Arm Shafts and Camshaft
9. INSTALLATION OF ROCKER ARM AND SHAFT ASSEM-

MD998443
BLY
(1) Insert the lash adjuster from below as illustrated, being *-
careful not to spill the diesel oil inside it. Then use the +
special tool to prevent adjuster from falling while
installing it.
(2) Place the rocker arm and shaft assembly on the cylinder
head and tighten the bearing cap bolt.
(3) Remove the special tool.
Lash adjuster 6EN248
8. APPLICATION OF SEALANT TO SEMI-CIRCULAR PACK-

Apply sealant
ING
Apply sealant on the periphery of the semi-circular packing.
lent
DEN230
10 mm
3EN0044
ENGINE <1.8L Engine> - Rocker Arms and Rocker Shafts
ROCKER ARMS AND ROCKER SHAFTS

R DISASSEMBLY AND REASSEMBLY
NOSNE-A
3EN0080
Disassembly steps
1. Rear camshaft bearing cap
2. Rocker arm
l 3. Wave washer
~~ 4. Camshaft bearing cap No. 4
5. Rocker shaft spring
l + 6. Camshaft bearing cap No. 3
~~ 7. Camshaft bearing cap No. 2
l + 8. Right rocker shaft
l 9. Left rocker shaft lybeverse the disassembly procedures to reassemble.
10. Front bearing cap (2) l : Refer to “Service Points of Reassembly”.
ENGINE <1.8L Engine> - Rocker Arms and Rocker Shafts
SERVICE POINTS OF DISASSEMBLY

NOTE
Before disassembly, mark the rocker arm for indentificahon.
INSPECTION NoaNGAG
ROCKER ARM
(1) Visually check the roller and replace if dent, damage, or
seizure is evident.
(2) Check roller for smooth rotation. Replace if it is binds or
there is an excessive play.
7EN0064
(3) Check the inside diameter and replace the rocker arm if
I I damage or seizure is observed.
I Cuts in rocker shafts
SERVICE POINTS OF REASSEMBLY NOBNHBC
9./8. INSTALLATION OF ROCKER AeM SHAFTS

Insert the rocker shafts into the holes in front bearing cap
and temporarily install the bolts to hold the shafts in place.
When the rocker arm shafts are inserted, make sure that
the shaft front end cuts are facing up as shown.
I 3EN021
Rocker cove1 7./6./4. INSTALLATION OF BEARING CAPS

Front mark
Cap No. attaching
The No. 2, No.3 and No.4 caps look alike in shape. Install
correct one at correct position. They can be identified by
the front mark, cap number and rocker cover attaching bolt
hole as illustrated.
No.2 No.3 No.4

3EN0093
3. INSTALLATION OF WAVE WASHER

Install the wave washer in correct direction as shown.
3EN0081
ENGINE <1.8L Engine> - Cylinder Head and Valve 9-53
CYLINDER HEAD AND VALVE
-’ DISASSEMBLY AND REASSEMBLY NDSPE-A
C;;d ;;g$;
51154 ftlbs.
, tP-----5
1
g-.-a &
105 y----2 g&---l4
Disassembly steps
+e ~~ I. Cylinder head bolts
2. Washer
3. Cylinder head
4. Gasket
+e l + 5. Retainer lock
6. Valve spring retainer
l + 7. Valve spring
~~ 8 . Intakevalve
+e e+ 9. Retainer lock
10. Valve spring retainer
l a 11. Valve spring
l + 12. Exhaust valve
+* l 4 13. Valve stem seal 3EN289
l 4 14. Valve spring seat
4I) l * 15. Valve stem seal
l + 16. Valve spring seat
17. Intake valve guide
18. Exhaust valve guide NOTE
(I) Reverse the disassembly procedures to reassemble.
19. Intake valve seat (2) +e : Refer to “Service Points of Disassembly”.
20. Exhaust valve seat (3) ~~ : Refer to “Service Points of Reassembly”.
ENGINE - Cylinder Head and Valve

1. REMOVAL OF CYLINDER HEAD BOLTS
Loosen the bolts in the order shown.
Loosen them little by little and uniformly.
3EN123
Front of engine (Timing belt side)

c
1 EN025
5./9. REMOVAL OF RETAINER LOCKS

(1) Using the special tool, remove the retainer locks.
(2) Keep the removed retainer locks valve by valve so that
they can be reinstalled in their original positions. A
3EN324
13.115. REMOVAL OF VALVE STEM SEAL

Remove the stem seals with pliers. Do not reuse the valve
stem seal.
ENGINE - Cylinder Head and Valve 9-55
INSPECTION
CYLINDER HEAD NosocAM
l Check the cylinder head for cracks, damage and engine
coolant leakage.
l Remove the scale, sealing compound and carbon deposits
completely. After cleaning oil passages, apply compressed
air to make certain that the passages are clear.
l Check the cylinder head gasket surface for flatness by
using a straight edge in the direction of A, B, . . . as shown. If
3EN026
the flatness exceeds the limit in any direction, either
resurface or replace the cylinder head.
Flatness of cylinder head gasket surface:
Standard dimension
Less than 0.05 mm (0020 in.)
Limit 0.2 mm (008 in.)
Overall height: 88.5 mm (3.484 in.)
Limit 88.3 mm (3.478 in.)
Caution
If cylinder block gasket surface has already been
ground, thickness of the removed stock should be
included in the grinding limit of -0.2 mm (-,008 in.).
VALVES No9PGMa
(1) Check each valve for wear, damage and deformation of
head and stem at B. Correct or replace excessively worn,
damaged or deformed valves.
(2) If stem tip A is pitted, correct with an oil stone or other
means. The correction must be limited to a minimum. Also
reface the valve.
(3) Replace the valve if the margin has decreased to less than
the limit.
w -w===j= Margin , EN034 Margin:
Standard dimension
Intake 1.0 mm (.039 in.)
Squareness Exhaust 0.7 mm (028 in.)
Limit
Intake 0.7 mm (.028 in.)
Exhaust 0.5 mm LO20 in.)
I Free length
VALVE SPRINGS NOWGh
(1) Check the valve spring for free length and load. If they
exceed the limits, replace the spring.
(2) Using a square, check the squareness of each spring. If the
spring is out of square beyond the limit, replace.
Valve spring:
Standard dimension
Free length 49.2 mm (1.937 in.)
Load 274.6 N (62 Ibs.) at installed height
Installed height 37.3 mm (1.469 in.)
Out of square Less than 2”
Limit
Free length 48.2 mm (1.888 in.)
Installed height 38.3 mm (1.516 in.)
Out of square 4”
9-56 ENGINE <1.8L Engine> - Cylinder Head and Valve
VALVE GUIDES
Check the valve stem-to-guide clearance. If the clearance 7-c.
exceeds the limit, replace the valve guide with a next higher
oversize guide. “I
Valve stem-to-guide clearance:
Standard dimension
Intake 0.03-0.06 mm (.0012-.0024 in.)
Exhaust 0.05-0.08 mm (.0020-.0035 in.)
Limit
Intake 0.10 mm (004 in.)
Stem O.D. YEN323
Exhaust 0.15 mm (.006 in.)
Valve Guide Oversizes
Size mm (in.) Size mark Valve guide fitting hole

diameter mm (in.)
0.05 l.002) OS. 5 13.05-13.068
(.5138-.5145)
0.25 LOlO) OS. 25 13.25-13.268
(.5216-.5244)
0.50 i.020) OS. 50 15.5-13.518
(.5315-.5323)
SERVICE POINTS OF REASSEMBLY

-I
15./ 13. INSTALLATION OF VALVE STE,M SEAL/l6./14.

VALVE SPRING SEAT
Install the spring seat, then using the special tool, install the -
stem seal by lightly tapping the tool. Seal is installed in -d
specified position using the special tool.
Caution
1. Incorrect installation of the seal without using the
special tool will result in poor sealing and cause oil
3EN0039 leakage down valve guide.
2. Do not reuse stem seal.
12.18. INSTALLATION OF EXHAUST, INTAKE VALVE

Apply engine oil to each valve. Insert valves into the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.
PL
ENGINE <1.8L Engine> - Cylinder Head and Valve 9-57
11./7. INSTALLATION OF VALVE SPRING
Spring Install the valve spring with its enamel coated end toward
Enamel- retainer the valve spring retainer.
coating
side
Stem seal
Spring
- seat
9.15. INSTALLATION OF RETAINER LOCK

(1) Using the special tool, compress the spring, and then
install the retainer lock.
Caution
When compressing the spring, check to see that the
valve stem seal is not pressed to the bottom of the
retainer.
(2) Make certain that retainer locks are positively installed.
3EN324
1. INSTALLATION OF CYLINDER HEAD BOLTS

Using the special tool, tighten in the order shown in two or
three steps, gradually tighten. Finally tighten to the speci-
fied torque.
3EN315
Front of engine I,
intake side
Exhaust side
9-58 ENGINE <1.8L Engine> - Front Case, Oil Pump and Silent Shaft
FRONT CASE, OIL PUMP AND SILENT SHAFT rl

i=G.
DISASSEMBLY AND REASSEMBLY NogRF-A
.r
8-12 Nm
6.0-8.5 ft.lbs. 15-22 Nm
11-15 ft.lbs.
I
1
26:
15-18 Nm
11-13 ftlbs.
25
Disassembly steps 18-25 Nm/

l + 1. Oil filter 13-18 ftlbs.
~~ l + 2. Oil pressure switch
3. Oil pressure gauge unit
4. Oil filter bracket
5. Gasket
6. Drain plug
7. Drain plug gasket
+e*+ 8. Oil pan 8-8 Nm
9. Oil screen 4-8 ft.lbs.
10. Oil screen gasket
11. Oil pump cover 3EN0088
l + 12. Oil pump oil seal
l + 13. Oil pump gasket
~~ l + 14. Flange bolt
I)+ 15. Oil pump driven gear 35-45 Nm
e+ 16. Oil pump drive gear 25-33 ftlbs.
+e l + 17. Front case
18. Plug
19. Relief spring
20. Relief plunger
l + 21. Silent shaft oil seal
l + 22. Crankshaft front oil seal
23. Front case gasket NOTE
24. Silent shaft, right (1) Reverse the disassembly procedures to reassemble.
25. Silent shaft, left (2) +e : Refer to “Service Points of Disassembly”.
4* l + 26. Silent shaft front bearing (3) l + : Refer to “Service Points of Reassembly”.
~~ l + 27. Silent shaft rear bearing (4) 0 : Non-reusable parts
L
ENGINE <l.$L Engine> - Front Case, Oil Pump and Silent Shaft 9-59
SERVICE POINTS OF DISASSEMBLY Nom&
2. REMOVAL OF PRESSURE SWITCH
(1) Disconnect the oil pressure switch terminal.
(2) Using the special tool, remove the oil pressure switch.
Caution
Sealant is coated on the threaded part, so be careful
not to damage when removing.
7Luooo5

(1) Remove the all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
oil pan.
NOTE
Never use a screwdriver or chisel, instead of the special
tool, as a deformed oil pan flange will result, resulting in
oil leakage.
14. REMOVAL OF FLANGE BOLT

When loosening the oil pump driven gear flange bolt, first
insert a Phillips screwdriver [shank diameter 8 mm (32 in.)]
into the plug hole on the left side of cylinder block to block
the silent shaft.
17. REMOVAL OF FRONT CASE

The front case may be sticking to the cylinder block. In such
a case, insert a screwdriver into the slot shown in the
illustration and pry up. Never attempt to pry at any other
positions where flange is thinner. Also avoid applying
impact to the front case for removal.
26. REMOVAL OF SILENT SHAFT FRONT BEARINGS

Using the special tool, remove the front bearing from
cylinder block.
MD998282
3EN041
S-60 ENGINE <1.8L Engine> - Front Case, Oil Pump and Silent Shaft
27. REMOVAL OF SILENT SHAFT REAR BEARING

Using the special tool, remove the rear bearing from A=
cylinder block. .i
INSPECTION
SILENT SHAFT NOSRUEl
(1) Check oil holes for clogging.

(2) Check journal for seizure, damage, and contact with
bearing. If there is anything wrong with the journal, replace
silent shaft, bearing or front case assembly.
(3) Check the silent shaft oil clearance. If the clearance is
excessively due to wear, replace the silent shaft bearing
silent shaft or front case assembly.
3EN040 Standard value:
Front
Right 0.030-0.060 mm (.0012-.0024 in.)
Left O.O20-0.064 mm (.OOOS-.0021 in.)
Rear
Right 0.050-0.091 m m (.0020-.0036 in.) rt
Left 0.050-0.091 mm (.0020-.0036 in.1
-4
FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check left silent shaft front bearing section for wear,
damage and seizure. If there is anything wrong with the
section, replace the front case.
(3) Check the front case for cracks and other damage. Replace
cracked or damaged front case.
OIL SEAL NOORCMAO
(1) Check the oil seal lip for wear and damage. Replace oil seal
if necessan/.
(2) Check the oil seal lip for deterioration. Replace oil seal if
necessary.
OIL PRESSURE SWITCH

(1) Connect a tester (ohm range) between the terminal and the
body and check for conductivity. If there is no conductivity,
replace the switch.
7LUOOO6
ENGINE <1.8L Engine> - Front Case, Oil Pump and Silent Shaft 9-61
(2) Next insert a very fine wedge through the oil hole, pushing
it slightly. There should be no conductivity (resistance
should be infinite). If there is conductivity even when
wedge is pushed, replace the switch.
(3) Or, if there is no conductivity when a 50 kPa (71 psi)
Fine pressure is placed through the oil hole, the switch is
operating properly. Check at this time to see that there is
no air pressure leakage. If there is air pressure leakage, the
diaphragm is broken, and the switch should be replaced.
7LUOOO7
OIL PUMP NomcGH

(1) Install the oil pump gears in the front case and check the tip
clearance of each gear using a thickness gauge.
Standard value:
Drive gear 0.06-0.12 mm (.0024-.0047 in.)
Driven gear 0.04-0.12 mm (.0039-.0079 in.)
Limit:
Drive gear 0.20 mm (.079 in.)
Driven gear 0.18 mm (.071 in.)
3LUOOOl
3LUOOO2
1 NOTE
Check the tip clearance of each gear at position indicated
by an arrow.
(2) Check the side clearance of each gear.

Standard value:
Drive gear 0.10-0.16 mm (.0039-.0063 in.)
Driven gear 0.02-0.05 mm (.0008-.0020 in.)
Limit:
Drive gear 0.20 mm (308 in.)
Driven gear 0.15 mm (AI66 in.)
(3) Check for ridge wear on the surface of the oil pump cover
that are in contact with the pump gear side.
I
9-62 ENGINE -4.8L Engine> - Front Case, Oil Pump and Silent Shaft
OIL RELIEF PLUNGER

(1) Check that the relief plunger slides smoothly.
(2) Check the relief spring for breakage.
SERVICE POINTS OF REASSEMBLY NOBRHAF
27. INSTALLATION OF SILENT SHAFT REAR BEARING

(1) Apply engine oil to the rear bearing outer circumference
and bearing hole in cylinder block.
(2) Using the special tool and a hammer, drive the rear
bearing into cylinder block.
26. INSTALLATION OF SILENT SHAFT FRONT BEARING

(1) Install two guide pins included in the special tool set to
the threaded holes in cylinder block.
(2) Set the front bearing on the special tool so that the
ratchet ball of special tool fits in the oil hole in bearing.
(3) Apply engine oil to the bearing outer circumference and
MD998280 bearing hole in cylinder block.
3EN044 J
(4) Set the special tool on guide pins and drive the bearing
into cylinder block.
22. INSTALLATION OF CRANKSHAFT OIL SEAL

0 M D998304 Using the special tool, install the crankshaft oil seal into
front case.
3EN270
ENGINE <1.8L Engine> - Front Case, Oil Pump and Silent Shaft 9-63
21. INSTALLATlON OF SILENT SHAFT OIL SEAL
Using a socket wrench, press-in the silent shaft oil seal into
a Socket wrench
/
front case.
3EN271
17. INSTALLATION OF FRONT CASE

MD998285
(1) Set the special tool on the front end of crankshaft and
apply engine oil to the outer circumference of the
special tool.
R Fasten toqether with

(2) Install the front case using three different sizes of bolts
the timtins under cover as shown.
C
Code Bolt size Head mark
(diameter x length) mm (in.)
A 8 x 20 (.32 x .79) “4”
B 8 x 25 (.32 x .98) “4”
C 8 x 40 (32 x 1.57) “4”
belt tensioner
3ENOOW
Timing marks 16. / 15. INSTALLATION OF OIL PUMP GEARS

(1) Align the timing mark on the drive gear with that on
driven gear and install them into front case.
(2) Apply amplely engine oil to the gears.
3EN046
14. INSTALLATION OF FLANGE BOLT

Insert a Phillips screwdriver [shank diameter 8 mm (32 in.)]
into the plug hole on the left side of cylinder block to block
the silent shaft, then tighten the flange bolt.
9-64 ENGINE 4.8L Engine> - Front Case, Oil Pump and Silent Shaft
13. INSTALLATlON OF OIL PUMP COVER GASKET

Install a new oil pump cover gasket in the groove of the
front case.
When installing the gasket, face the round side to the oil
Front case pump cover.
3LUOO3 I
12. INSTALLATION OF OIL PUMP OIL SEAL

Flat iron plate Install the oil seal into the oil pump cover, making sure that
its lip is in correct direction.
8. APPLICATION OF SEALANT TO OIL PAN

(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply sealant into groove of oil pan flange, ~keeping clear of
holes as shown. The width of sealant bead as sqeezed out
of tube should be about 4 mm (.I6 in.).
Caution
After application of sealant, do not exceed l’5 minutes
before installing the oil pan.
Specified sealant: MITSUBISHI GENUINE PART NO.
3EN184
MD997110 or equivalent
2. INSTALLATION OF OIL PRESSURE SWlTCH

MD998054 Coat the threads of switch with sealant and install the
/ switch using the special tool.
lent
Caution
1. Keep the end of threaded portion clear of sealant.
2. Avoid an overtightening.
1. APPLICATION OF ENGINE OIL TO OIL FILTER

Apply a thin coat of engine oil to the packing surface.
-----me ,.
Caution
t Do not apply oil too much.
Coat with
engine oil
6LUO26
ENGINE <1.8L Engine> - Piston and Connecting Rod 9-65
PISTON AND CONNECTING ROD MaTEA
S-- DISASSEMBLY AND REASSEMBLY
Disassembly steps
l 4 Inspection of connecting rod big end side
clearance
1. Nut 11. Piston
+e I)+ 2. Connecting rod cap 12. Connecting rod
3. Cpnnecting r o d bearing
l * 4. Piston and connecting rod assembly NOTE
5. Connecting rod bearing (1) Reverse the disassembly procedures to reassemble.
6. Bolt (2) 4e : Refer to “Service Points of Disassembly”.
++I)+ 7. No. 1 piston ring (3) l + : Refer to “Service Points of Reassembly”.
+e l + 8. No. 2 piston ring
l * 9. Oil ring
10. Piston pin 3EN275
9-66 ENGINE <1.8L Engine> - Piston and Connecting Rod
SERVICE POINTS OF DlSASSEMB&Y

2. REMOVAL OF CONNECTING ROD CAP
Put cylinder number on the side of the connecting rod big
end for identification in reassembly.
DENOSC
7. REMOVAL OF NO. 1 PISTON RING /8. NO.2 PISTON

RING
Remove the piston rings with a piston expander.
INSPECTION NoncM
PISTON AND PISTON PIN
(1) Replace the piston if it has marks of streaks or seizure on
the outside thrust surface in particular. Also replace if it has
cracks on the outside.
(2) If the piston pin can be inserted into the piston pink hole
snugly with a thumb, it is reusable. If it is inserted with no
resistance or there is a play, replace the piston and pin as a
set.
PISTON RINGS
(1) Measure the piston ring side clearance. If the measure-
ment exceeds the limit, insert a new ring in ring groove to
measure the side clearance. If the clearance still exceeds
the limit, replace the piston and rings together. If it is within
the limit replace the piston rings only.
Piston ring side clearance:
No. 1 0.045-0.085 mm (.0018-.0033 in.)
No.2 0.02-0.06 mm (.0008-.0024 in.)
Limit:
\J 5EN05;
No. 1 0.12 mm (.005 in.)
No.2 0.1 mm (.004 in.)
%Press down with piston%
(2) To measure the piston ring end gap, insert a piston ring into
cylinder bore. Correctly position the ring at right angles to
the cylinder wall by gently pressing it down with a piston.
Draw the piston up and out, then measure the gap with a
feeler gauge. If the gap exceeds the limit, replace the
piston ring.
Piston ring End gap 6EN037

ENGINE <1.8L Engine> - Piston and Connecting Rod 9-67
Piston ring end gap:
Standard dimension
No. 1 0.30-0.45 mm (.0118-.0177 in.)
No.2 0.20-0.35 mm (.0079-.0138 in.)
Limit 0.8 mm LO31 in.)
Oil ring side rail:
Standard dimension 0.2-0.7 mm (.008-.028 in.)
Limit 1.0 mm (.039 in.)
When replacing the ring only without correcting the
cylinder bore, check the gap with the ring positioned at a
lower part of cylinder that is less worn.
When replacing a ring, be sure to use a ring of the same
size.
Piston ring service size and mark:
STD None
0.25 mm (.OlO in.) O.S. 25
0.50 mm (020 in.) O.S. 50
0.75 mm (030 in.) O.S. 75
1.00 mm (039 in.) B.S. 100
CONNECTION RODS NOSTCCA
(1) Replace the connecting rod if it has damage on thrust faces

at either end. Also replace the connecting rod that has ridge
wear or severely rough surface on the inside diameter of
the small end.
When using a new connecting rod, the cylinder number
should be stamped in two places, on the cap and on the
rod.
(2) Using a connecting rod aligner, check the rod for bend and
twist. If the measured value is close to the limit, correct the
rod using a press. Any connecting rod that has been
severely bent or distorted should be replaced.
Bend of connecting rod:
0.05/100 mm (.0020/3.937 in.) or less
Twist of connecting rod:
O.l/lOO mm (.004/3.937 in.) or less
SERVICE POINTS OF REASSEMBLY NOSTGEA
9. INSTALLATION OF OIL RING

(1) First, install the oil ring spacer in the piston ring groove.
Next, install the upper side rail and then the lower side
rail. Both upper and lower side rails may be installed
with their either side facing up.
(2) To install the side rail, first place one end in the gap
between the groove and the spacer.
While holding the end firmly, press the portion to be
inserted with finger as illustrated until the side rail is in
position.
Caution
Do not use piston ring expander to install the side
rail.
9-68 ENGINE <1.8L Engine> - Piston and Connecting Rod
r- Size and maker marks 8. INSTALLATION OF NO.2 PISTON RING/7. NO. 1

PISTON RING
No. 1 Barrel Install the No. 2 piston ring and then the No. 1 piston ring
faced with a piston ring expander.
I
1 Caution
1 Size and maker marks 1. The No. 1 and No.2 piston rings have a different
LNo.2
ti2zza
Barrel
Tapered
cross section. Be sure to install them in correct
positions.
2. Install the No. 1 and No.2 piston rings with the size
mark and maker mark on ring surface toward the
faced
piston top.
1 EN064
-1 N o . 1 rina aar 4. INSTALLATION OF PISTON AND CONNECTlNG ROD

ASSEMBLY
(1) Liberally coat engine oil on the circumference of the
piston, piston ring, and oil ring.
Gap of (2) Arrange the piston ring and oil ring gaps (side rail and
upper spacer) as shown in the figure.
(3) Rotate crankshaft so that crank pin is on center of
cylinder bore.
(4) Use suitable thread protectors on connecting rod bolts

before inserting piston and connecting rod assembly
into cylinder block. Care must be taken not to nick crank
pin.
(5) Using a suitable piston ring compressor tool, install
piston and connecting rod assembly into cylinder block.
Caution
Insert the front mark (arrow) on the top of the
piston so it faces the engine front (timing belt side).
2. INSTALLATION OF CONNECTING ROD CAP

Lining up the marks put at the time of disassembly, install
the connecting rod cap on the connecting rod.
If the connecting rod is new without such marks, position
the bearing block tab notches in rod and cap on the same
side as illustrated.
Bearing bl
tab notches
DEN057
. CHECKING CONNECTING ROD BIG END SIDE CLEAR-

ANCE
Connecting rod big end side clearance:
0.1-0.25 mm (.0039-.0098 in.)
Limit: 0.4 mm (016 in.)
ENGINE <1.8L Engine> - Crankshaft, Flywheel and Drive Plate S-69
CRANKSHAFT, FLYWHEEL AND DRIVE PLATE
- DISASSEMBLY AND REASSEMBLY 130-140 Nm NONE-A
94-101 fths.
I I
FORWARD
3EN320
4
6 Disassembly steps
1. Flvwheel Vehicles with a
2. Ri’ng gear manual transaxle
3. Adaoter 7
?!w -13 4. 5. Drive plate
Adapter plate
IVehicles.with an
automatrc transaxle
6. Crankshaft bushing
7. Rear plate
8. Bell housing cover
12 l * 9. Rear oil seal
10. Oil seal case
11. Gasket
50-55 Nm l + 12. Bearing cap
37-39 ft.lbs. W 13. Lower bearing
14. Crankshaft
I)* 15. Upper bearing
NOTE
INSPECTION NOSUHAC
CRANKSHAFT
(1) Check the crankshaft journals and pins for damage, uneven
wear and cracks. Also check oil holes for clogging. Correct
or replace any faulty part.
(2) Inspect out-of-round and taper of crankshaft journal and
pin.
Standard dimension:
Crankshaft journal O.D. 57 mm (2.24 in.)
Crank pin O.D. 45 mm (1.77 in.)
Crankshaft journal pin out-of-round and taper
Less than 0.015 mm (.0006 in.)
ENGINE <1.8L Engine> - Crankshaft, Flywheel and Drive Plate
MAIN BEARINGS AND CONNECTING ROD BEARINGS

Visually inspect each bearing for peeling, melt, seizure and
improper contact. Replace the faulty bearings.
OIL CLEARANCE MEASUREMENT
To check the oil clearance, measure the outside diameter of
crankshaft journal and crank pin and the inside diameter of
bearing. The clearance can be obtained by calculating the
difference between the measured outside and inside dia-
meters.
Oil clearance:
Crankshaft main bearing
0.02-0.05 mm (.OOOS-.0019 in.)
Connecting rod bearing
0.02-0.05 mm (.OOOS-.0019 in.)
Limit:
Crankshaft main bearing 0.1 mm (.004 in.)
Connecting rod bearing 0.1 mm (.004 in.)
3EN055
PLASTIC-GAUGE METHOD
Plastic-Gauge may be used to measure the clearance.
(1) Remove oil and grease and any other dirt from bearings and
journals.
(2) Cut Plastic-Gauge to the same length as the width of the
bearing and place it in parallel with the journal, off oil holes.
(3) Install the crankshaft, bearings and caps and tighten them
to the specified torques. During this operation, do NOT turn
the crankshaft. Remove the caps. Measure the width of the
Plastic-Gauge at the widest part by using a scale printed on
6EN043 the Plastic-Gauge sleeve.
If the clearance exceeds the limit, the bearing should be
replaced or an undersize bearing used.
When installing a new crankshaft, be sure to use standard
size bearings.
Should the standard clearance not be obtained even after
bearing replacement, the journal should be ground to
undersize and a bearing of the same size should be
installed.
1 EN067
OIL SEAL
Check front and rear oil seals for damage or worn lips.
Replace any seat that is faulty.
ENGINE - Crankshaft, Flwvheel and Drive Plate 9-71
RING GEAR (Engine with a manual transaxle)
Check the ring gear for worn, damaged or broken teeth.
Replace the ring gear if teeth are faulty, and also check the
starter motor pinion.
Ring Gear Replacement Procedure
(1) Strike outer circumference of ring gear at several points.
Caution
The ring gear cannot be removed if it is heated.
(2) Install the ring gear on flywheel after heating the ring gear
3EN30’ I
to 260-280°C (500-536°F) for shrink fit.
FLYWHEEL (Engine with a manual transaxle)
(1) Visually check the clutch disc friction surface of flywheel for
ridge wear, streaks and seizure. Replace as necessary.
(2) If the flywheel runout exceeds the limit, replace it.
Limit: 0.13 mm (0051 in.)
DRIVE PLATE (Engine with an automatic transaxle)
Replace if deformed, damaged or cracked.
SERVICE POINTS OF REASSEMBLY NOSUDAA
15. INSTALLATION OF UPPER BEARING

When reusing the main bearings, install them in their
original positions by referring to location marking made at
the time of removal.
Be sure that oil holes in bearings align with those in cylinder
block.
13. INSTALLATION OF LOWER BEARING
Make sure that a bearing without oil groove is used as
lower bearing.
12. INSTALLATION OF BEARING CAP
lrrow mark toward cap No,
(1) Install the bearing caps with their arrow mark directed
toward the timing belt side of engine. Cap numbers
must be in correct order.
(2) Tighten cap bolts in the sequence of center, No.2,
No.4. front and rear cap bolts.
(3) Cap bolts should be tightened evenly in 2 to 3 steps
before they are finally tightened.
(4) Make certain that the crankshaft turns freely and has a
proper end play by checking the clearance between
center main bearing thrust flange and connecting rod
big end bearing.
Crankshaft end play:
0.05-0.18 mm (.0020-.0071 in.)
Limit: 0.25 mm (.0098 in.)
9-72 ENGINE <1.8L Engine> - Crankshaft, Flywheel and Drive Plate/Cylinder Block
9. INSTALLATlON OF REAR OIL SEAL

Press
Oil seal Install oil seal in the crankshaft rear oil seal case. Using the iii
MD99801 1
special tool, press fit the oil seal all the way in without tilting
I /
it.
1
i
/
/
Oil seal case
1 EN06 9
L
CYLINDER BLOCK
DISASSEMBLY AND REASSEMBLY FORWARD NDBVF-A
110-130 Nm
80-94 ft.lbs.
50-70 Nm
37-50 ft.lbs.
30-42 Nm
22-30 ft.lbs.
1. Exhaust pipe support bracket 4. Left engine support bracket

2. Front roll stopper bracket 5. Cylinder block
3. Rear roll stopper bracket 6. Engine mount bracket
3EN0092
INSPECTION
l Visually check the cylinder block for scores, rust and
corrosion. Also check for cracks or any other faults by using
the magnaflux method. Correct or replace the block if
faulty.
l Measure the cylinder bore with a cylinder gauge at three
levels and in two directions A and B as shown. If
out-of-round or taper is more than specified or if the
cylinder walls are badly scuffed or scored, the cylinder &
block should be rebored and honed, and new oversize _
pistons and rings fitted.
Measuring points are as shown.
Cylinder bore: 80.8 mm (3.173 in.)
Out-of-round and taper: 0.01 mm (.0004 in.)
ENGINE <1.8L Engine> - Cylinder Block 9-73
l If cylinder top ridge is worn in stages, smooth out with a
ridge reamer.
l Oversize pistons are available in four sizes.
Piston oversizes and marks:
0.25 mm (.OlO in.) OS. 0.25
0.50 mm (.020 in.) O.S. 0.50
0.75 mm (.030 in.) O.S. 0.75
1 .OO mm (.039 in.) O.S. 1.00
l To rebore the cylinder to an oversize, keep the specified
clearance between the oversize piston and the bore, and
make sure that all pistons used are of the same oversize.
The standard measurement of the piston outside diameter
is taken at a level 2 mm (0787 in.) above the bottom of the
piston skirt and across the thrust faces.
Piston-to-cylinder wall clearance:
0.01-0.03 mm (.0004-.0012 in.)
l Check for damage and cracks.

l Check top surface for flatness. If excessive distortion is
evident, grind minimum stock within the limit or replace.
Flatness of gasket surface:
Standard Less than 0.05 mm (0020 in.)
Limit 0.1 mm (.004 in.)
Overall height: 285.2 mm (11.228 in.)
Limit 285 mm (11.220 in.)
Caution
If cylinder head gasket surface has already been
ground, the thickness of the removed stock should be
included in the grinding limit of -0.2 mm (-.008 in.).
CYLINDER REBORING NOBVEBA
(1) Determine the oversize pistons to be used with reference

to the cylinder with the largest bore.
(2) Measure the piston O.D. at the measuring point.
NOTE
There are four piston oversizes available: 0.25 mm (.OlO
Thrust in.), 0.50 mm (.020 in.), 0.75 mm (.030 in.) and 1.00 mm
directiol (.039 in.).
(3) Based on the measured piston O.D., calculate the boring
dimension as follows:
6ENOd Boring dimension = [Piston O.D.] + [Piston-to-cylinder
clearance 0.03 to 0.05 mm (.0012 to .0020 in.)] - [Honing
allowance 0.02 mm (.0008 in.)]
(4) Bore each cylinder to the calculated boring dimension.
Caution
To prevent distortion caused by temperature rise
during boring, work in the order of No.2 to No.4 to
No. 1 to No.3 cylinders.
(5) Hone to final finish dimension [Piston O.D.] + [Piston-to-
cylinder clearance].
(6) Check piston to cylinder clearance.
9-74 ENGINE <2.0L DOHC Engine> - Service Adjustment Procedures
ENGINE <2.0L DOHC Engine>

SERVICE ADJUSTMENT PROCEDURES pi
CHECKING COMPRESSION PRESSURE NOSFFAH
(1) Before checking compression, ensure that engine oil, the

starter motor, and battery are all in good condition.
(2) Start the engine and wait until engine coolant temperature
has risen to 85-95°C (185-205°F).
(3) Stop the engine and pull the spark plug cables.
(4) Remove the spark plugs.
(5) Crank the engine to. remove any foreign objects in the
cylinders.
Caution
Cover the spark plug holes with shop towel, etc., in
order to keep expelled foreign objects from flying out,
and keep away from the holes. When measuring
compression with water, oil, or fuel having entered the
cylinder through a crack, etc., these will come flying
out of the spark plug hole hot and fast, so be sure to
take the proper precautions.
(6) Set the compression gauge to the spark plug hole.
(7) Holding the throttle valve full open, crank the engine and
measure compression.
Limit:
<Non-Turbo>: Min. 960 kPa (137 psi)
[250-400 rpm] 6
<Turbo>: Min. 800 kPa (114 psi) [250-400 rpml -
(8) Perform 6 and 7 above for all the cylinders, ensuring that
compression pressure differential for each of the cylinders
is within the specified limit.
Differential limit: Max. 100 kPa (14 psi)
(9) If a cylinder’s compression or pressure differential exceeds
the limit, add a small amount of oil through the spark plug
hole and repeat steps (6)-(8).
@ If the addition of oil brings compression up, it is possible
that there is poor contact between the piston ring and
cylinder wall.
@ If not compression does not come up, valve seizure,
poor valve seating, or a compression leak from the
gasket are all possible.
‘I
ENGINE <2.0L DOHC Engine> - Service Adjustment Procedures 9-75
MANIFOLD VACUUM INSPECTION NO9FNAO
(1) Before inspection and adjustment, put the vehicle into the
_-
following state.
l Engine coolant temperature: 85-g5”C (185-205°F)
l Lights, electric, cooling fan, and accessories: OFF
l Transaxle: Neutral (N or P for vehicles with an automa-
tic transaxle)
l Steering wheel: Neutral position
(2) Check that the idling revolution speed is normal.

(3) Remove the PCV hose from the PCV valve and attach a
vacuum gauge.
(4) Check that the negative pressure at the intake manifold
during idle revolution is normal.
Standard value:
<Non-Turbo>: 490 mmHg (19.3 in.Hg)
<Turbo>: 480 mmHg (18.9 in.Hg)
(5) If outside the standard value, isolate the cause by referring
to the following table and repair the fault.
J
ymptom IC ause 1 Remedy
The vacuum gauge reading is less than l Ignition timing is retarded. l Adjust the ignition timing.
standard value, but the pointer is
a-- stable.
The vacuum gauge pointer swings l Air mixture concentration too l Check ECI-MULTI system.
slowly. rich.
The vacuum gauge pointer drops irre- l Air mixture concentration too l Check ECI-MULTI system.
gularly. lean.
The vacuum gauge pointer drops inter- l Incomplete close contact of in- l Check and repair the valve.
mittently to 30 to 160 mmHg (1.2 to take and exhaust valve seat.
6.3 in.Hg).
The vacuum gauge pointer drops sud- l Broken cylinder head gasket l Replace cylinder head gasket.
denly from the normal reading to 250
mmHg (9.8 in.Hg), then returns to
normal.
9-76 ENGINE <2.0L DOHC Engine> - Service Adjustment Procedures
LASH ADJUSTERS CHECK NOBFEABal
If an abnormal noise is heard from the lash adjusters check as

follows.
(1) After warming up the engine, stop it.
(2) While installed to the cylinder head, press the part of rocker
arm that contacts the lash adjuster. The part pressed will
feel very hard if the lash adjuster condition is normal.
(3) If, when pressed, it easily descends all the way downward,
replace the lash adjuster.
(4) If there is a spongy feeling when pressed, air is probably
mixed in, and so the cause should be investigated. The
cause is probably an insufficient amount of engine oil, or
damage to the oil screen and/or screen gasket.
(5) After finding the cause and taking the appropriate step
(adding oil or repair), warm up the engine and drive at low
speed for a short time. Then, after stopping the engine and
waiting a few minutes, drive again at low speed. Repeat
this procedure a few times to bleed out the air from the oil.
ENGINE <2.0L DOHC Engine> - Engine Mounting 9-77
ENGINE MOUNTING NOBGA-B
- REMOVAL AND INSTALLATION
*Raise and Suspend the Engine to the

Extent Force is not applied to the Engine
@Lower the Engine 50-65 Nm
36-47 ftlbs.
50-65 Nm
36-47 ftlbs.
Removal steps OlAO559

I
1. Pressure hose (power steering)
2. Bracket
3. Engine mount bracket and body
connection bolt NOTE
4. Engine mount bracket (1) Reverse the removal procedures to reinstall.
l + 5. Mounting stopper (2) *+ : Refer to “Service Points of Installatron”.
INSPECTION NOSGCAHJ

SERVICE POINTS OF INSTALLATION NOSGDAKl

Engine side Mounting stopper
CI
5. INSTALLATION OF MOUNTING STOPPER
Install the mounting stopper of the engine mount bracket
so that the arrow faces the center part of the engine.
Anow
OlA0004
9-78 ENGINE <2.0L DOHC Engine> - Transaxle Mounting
TRANSAXLE MOUNTING No9GE-6

l installation of the Air Cleaner
40-50 Nm
29-36 ftlbs.
/
60-80 Nm
43-58 ftlbs.
6 Transaxle
mount
bracket
OlA0645
<A/T>
*
6
40-50 Nm 2
6
5”
60-80 Nm/ -f-h
Removal steps 43-58 ftlbs. 6 1t
4* I. ABS hydraulic unit

2. Transaxle mount bracket and transaxle
connection bolt
3. Caps NOTE
4. Transaxle mount bracket installation bolts (I) Reverse the removal procedures to reinstall.
5. Transaxle mount bracket (2) +* : Refer to “Service Points of Removal”.
6. Mounting stopper (3) *: <Vehicles with ABS>
SERVICE POINTS OF REMOVAL NO9GEAA
1. REMOVAL OF ABS HYDRAULIC UNIT

Refer to GROUP 5-Hydraulic Unit.
INSPECTION NOSGCAH4

l Check each bracket for deformation or dsmage.
ENGINE <2.0L DOHC Engine> - Engine Roll Stopper 9-79
ENGINE ROLL STOPPER NOSGF-B

40-50 Nm
<FWD> 29-36 ft.lbs.
l Raise and Suspend the Engine to the

@Lower the Engine
<AWD> 1
3
40-50 Nm
40-50 Nm 29-36 ft.lbs.
29-36I ft.lbs. n /5
/4
Front roll stopper bracket removal steps
1. Front roll stopper bracket and engine
\ connection bolt
2. Front roll stopper bracket installation bolts
X
l + 3. Front roll stopper bracket
Rear roll stopper bracket removal steps
4. Rear roll stopper bracket and engine
connection bolt
5. Rear roll stopper bracket installation bolts
l + 6. Rear roll stopper bracket
50-65 Nm
36-47 ftlbs. NOTE
(4) For tightening locations indicated by the * symbol, fjrst
tighten temporarily, and then make the final tightenrng
with the entire weight of the engine applied to the
vehicle body.
INSPECTION NOSGCAHS

9-80 ENGINE <2.0L DOHC Engine> - Engine Roll Stopper
SERVICE POINTS OF INSTALLATION N-$?y

Rear roll
6. INSTALLATION OF REAR ROLL STOPPER BMFKE?
<Vehicles with AWD-A/T> , (1 ;r.
After temporarily tightening the rear roll stopper bracket,
tighten so that, in the unladen vehicle condition, the
-92 .7 mm
-3.6 in.) distance from the center hole of the insulator to th:e lower
edge of the bracket is the specified distance.
12A0638 J
3. INSTALLATION OF FRONT ROLL STOPPER BRACKET

Forward (1) Install the front roll stopper bracket so that the part
0 where the round hole is made is facing the front of the
vehicle.
:fYVD> Front roll (2) After temporarily tightening the front roll stopper
stopper bracket bracket, tighten so that, in the unladen vehicle condi-
/ tion, the distance from the center hole of the insul&tor
to the lower edge of the bracket is the specified -
distance.
jl.7-57.7 mm
2.0-2.3 in.)
olR003t I
Front roll
<AWD-M/T>
44-50 mm
(1.7-2.0 in.)
OlAO610
ENGINE <2.0L DOHC Engine> - Engine Assembly
ENGINE ASSEMBLY
- REMOVAL AND INSTALLATION 4-6 Nm
l Eliminating Fuel Pressure in Fuel Line
Procedures.)
*Removal of Engine Hood
@Draining of Engine Coolant
(Refer to GROUP 7-Service Adjustment Pro-
cedures.)
*Removal of the Transaxle Assembly
*Removal of the Radiator
*Removal of Under Cover Left
15
I
\ I / MAO571
;- 19
@Installation of Under Cover Left

26'
*Installation of the Transaxle Assembly
I l Refilling of Enaine Coolant
/ 22/ 4-6 ‘ N m \ (Refer t’o GROUP 7-Service Adjustment Pro-
21
Removal steps
3-4 ftlbs. 23 cedures.)
l Installation of Engine Hood ‘I
~~ 1. Connection for accelerator cable or 16. Connection for engine coolant
throttle cable temperature switch (Air conditioner)
2. Connection for accelerator cable (Auto- 17. Connection for crank angle sensor
cruise control) 18. Connection for TPS
3. Connection for fuel return hose 19. Connection for ISC and idle switch
4. Connection for brake booster vacuum 20. Connection for fuel injectors
hose 2 1. Connection for ignition coil
5. Connection for solenoid valve (Turbo) 22. Connection for power transistor
6. Solenoid valve bracket (Turbo) 23. Connection for knock sensor (Turbo)
7. Connection for air hose A (Turbo) 24. Connection for EGR temperature sensor
8. Connection for air hose C (Turbo) (California vehicles only)
9. Connection for fuel high pressure hose 25. Connection for ground cable
10. O-ring 26. Control wiring harness
11. Connection for heater hoses
12. Connection for vacuum hoses
13. Connection for oxygen sensor
14. Connection for engine coolant NOTE
temperature sensor (I) Reverse the removal procedures to reinstall.
15. Connection for engine coolant (2) e+ : Refer to “Service Points of Installation”.
temperature gauge unit (3) m : Non-reusable parts
9-82 ENGINE <2.0L DOHC Engine> - Engine Assembly
23-27 Nm
/ 17-20 ftlbs.
60-60 Nm
43-58 ft.lbs.
50-65 Nm*
36-47 ft.lbs.*
.--
<Non-Turbo>
30-40 Nm
22-29 ftlbs. OlAO561
1 <Turbo>
40-60 Nm
I 29-43 ft.lbs.
27. Connection for oil pressure switch (Power 39. Self-locking nut
steering) +e l + 40. Engine assembly
28. Connection for alternator
29. Alternator wiring harness clamp
30. Connection for oil pressure switch NOTE
31, Connection for oil pressure gauge unit (I) Reverse the removal procedures to reinstall.
l + l * 32. Power steering oil pump (2) l * : Refer to “Service Points of Removal”.
+9 ~~ 33. Air conditioner compressor (3) I)+ : Refer to “Service Points of Installation”.
34. Self-locking nuts (4) m : Non-reusable parts
35. Gasket (5) For tightening locations indicated by the * symbol, first
36. Pressure hose (Power steering) tighten temporarily, and then make the final tightening
37. Bracket with the entire weight of the engine applied to the
4* 38. Engine mount bracket vehicle bodv.
SERVICE POINTS OF REMOVAL NOSSBDFa

NOTE
The removed power steering oil pump should be fastened A
the removal/installation of the engine assembly.
ENGINE <2.0L DOHC Engine> - Engine Assembly S-83
33. DISCONNECTION OF AIR CONDITIONER COMPRESS-
OR
Disconnect air conditioner compressor connector and
remove it with hoses from the compressor bracket.
NOTE
The removed air conditioner compressor should be fas-
tened (by using rope, etc.) in a position that will not
interfere with the removal/installation of the engine assem-
bly.
OlA0177
38. DISCONNECTION OF ENGINE MOUNT BRACKET

Before removing the engine mount bracket installation bolt,
use a chain block or similar arrangement to suspend the
engine assembly (to the extent that there is no looseness
of the chain).
40. DISCONNECTION OF ENGINE ASSEMBLY
After checking that the cables, hoses, harness connectors,
etc. are all removed, slowly raise the chain block to lift the
engine assembly upward out of the engine compartment.
-mpp.-/- --
OlA0553
SERVICE POINTS OF INSTALLATION NOSSDAU
40. INSTALLATION OF ENGINE ASSEMBLY

When mounting the engine, check to be sure that the
r-.
cables, hoses, harness connectors, etc. are all in the
correct position.
33. INSTALLATION OF AIR CONDITIONER COMPRESSOR
32. INSTALLATION OF POWER STEERING OIL PUMP
Refer to GROUP 1 g-service Adjustment Procedures.
1. ADJUSTMENT OF ACCELERATOR CABLE
9-84 ENGINE <2.0L DOHC Engine> - Camshafts and Camshaft Oil Seals
CAMSHAFR AND CAMSHAR OIL SEALS

REMOVAL AND INSTALLATION No8u-s
ppEJ=-j
2.5-3.5 Nm 2.5-3.5 Nm
2 - 3 ft.lbs. 2 - 3 ft.lbs.
lo-13 Nm
olmlzo
++ 10. Crankshaft angle sensor
a* 11. Exhaust camshaft sprocket
80-100 Nm 4* 12. Intake camshaft sprocket
58-72 ftlbs. +e *+ 13. Camshaft oil seals
+e e+ 14. front camshaft bearing caps
Removal steps 41) +4 15. Camshaft bearing caps
l + 1. Connection for accelerator cable or +e +c 16. Rear camshaft bearing cap (R.H.)
throttle cable +e +4 17. Rear camshaft bearing cap (L.H.)
d+ l b 2. Timing belt ~~ 18. Exhaust camshaft
3. Center cover +q 19. intake camshaft
4. Connection for breather hose NOTE
5. Connection for PCV hose (1) Reverse the removal procedures to reinstall.
6. Connection for spark plug cables (2) 4* : Refer to “Service Points of Removal”.
l + 7. Rocker cover (3) l a : Refer to “Service Points of Installation”.
~~ 8. Semi-circular packing (4) m : Non-reusable parts
9. I hrottle body stay *I: <Non-Turbo>
1:; ~2: <Turbo>
SERVICE POINTS OF REMOVAL No9zsAB

Refer to P.9-98.
ENGINE <2.0L DOHC Engine> - Camshafts and Camshaft Oil Seals 9-85
11. REMOVAL OF EXHAUST CAMSHAFT SPROCKET/
12. INTAKE CAMSHAFT SPROCKET
(1) Using a wrench at the hexagonal part of the camshaft
(to prevent the crankshaft from turning), loosen the
cramshaft sprocket bolt.
(2) Remove the camshaft sprokets.
13. REMOVAL OF CAMSHAFT OIL SEALS

Remove the oil seals using a screwdriver or similar tool.
Caution
Take care not to damage front camshaft bearing cap
and camshaft.
14./15./16./17. REMOVAL OF CAMSHAFT BEARfNG CAPS
(1) Loosen the bearing cap installation bolts in two or
three steps.
(2) Remove the bearing cap.

Plastic hammer
NOTE
If the bearing cap is difficult to remove, use a plastic
hammer to gently tap the rear .part of the camshaft,
and then remove.
SERVICE POINTS OF INSTALLATION NO92DAB
lg. INSTALLATION OF INTAKE CAMSHAFT/18. EXHAUST

Intake side Exhaust side
CAMSHAFT
(22
(1) Install the camshafts on the cylinder head.
Slits
Jzzl Caution
Be sure not to mistake the intake side and the
exhaust side. There are slits for crank angle sensor
drive in the rear end of the intake camshaft.
NOTE
Install new camshafts using the following procedure.
(1) Remove the rocker arms.
(2) Lay the camshafts on the cylinder head and install
the bearing caps.
(3) Check that the camshaft can be easily turned by
hand.
(4) After checking, remove the bearing caps and the
camshafts, and install the rocker arms.
9-86 ENGINE <2.0L DOHC Engine> - Camshafts and Camshaft Oil Seals
(2) The camshaft’s dowel pins should be at the positions
shown in the figure. _-
‘7
17./16./15./14. INSTALLATION OF CAMSHAFT BEARING

CAPS
Tighten the bearing cap installation bolts to the specified
torque in two or three steps.
Caution
Tighten uniformly, otherwise the rocker arms will not
be straight.
r MD998306 qil seal 13. INSTALLATION OF CAMSHAFT OIL SEALS

Using the special tool, press in the oil seal as shown in the
figure.
coati
the
mrence
of the guide. 6EN612
Mating mark at Mating mark at 10. INSTALLATION OF THE CRANKSHAFT ANGLE SENSOR
(1) Align the mating mark (punch mark) on the housing of
the crank angle sensor with the mating mark (notch) in
the plate.
(2) Install the crank angle sensor to the engine.
Caution
When tightening the nut of the crankshaft angle
sensor, make sure that the crank angle sensor does
not turn.
llA0361 (3) Check that the ignition timing is set at the standard
value. (Refer to GROUP 8-Ignition System.)
Awlv sealant 8. INSTALLATION OF SEMI-CIRCULAR PACKING

Install the semi-circular packing to the cylinder head, and
apply a coating of the specified sealant where shown in
the figure. Ak
Specified sealant: MOPAR Part No.4318034
or equivalent
Semi-circular packing
ENGINE <2.0L DOHC Engine> - Camshafts and Camshaft Oil Seals/Oil Pan and Oil Screen 9-87
7. INSTALLATION OF ROCKER COVER
Apply a coating of the specified sealant where shown in
the figure, and then install the rocker cover to the cylinder
head assembly.
mm or equivalent
in.)
Apply sealant
olmO47
2. INSTALLATION AND ADJUSTMENT OF TIMING BELT

Refer to P.9-104.
Refer to GROUP 14-Service adjustment procedures.
OIL PAN AND OIL SCREEN NO9HA-B
REMOVAL AND INSTALLATION /
/j<&
\ I/“! 18
50-65 Nm*
36-47 ft.lbs.*
III13
12-
Removal steps
1. Drain plug
2. Self locking nut 15-22 Nm
3. Centermember 11-16 ft.lbs.
7. Connection for exhaust pipe
8. Gasket
9. Connection for oil return pipe (Turbo:
IO.
l * l * 11.
Gasket (Turbo)
Oil pan
/
11 7‘ 1
12. Oil screen 35-45 Nm I
13. Gasket 25-33 ft.ll3s.
NOTE
(I) Reverse the removal procedures to reinstall. (5) For tightening locations indicated by the * symbol, first
(2) l e : Refer to “Service Points of Removal”. tighten temporarily, and then make the final trghtenrng
(3) l + : Refer to “Service Points of Installation”. with the entire weight of the engine applied to the
(4) m : Non-reusable parts vehicle body.
9-88 ENGINE <2.0L DOHC Engine> - Oil Pan and Oil Screen
<I(Refer to GROUP 0-Maintenance
<AWD>
40-60 Nm
30-40 Nm
22-29 ft.lbs..
/ 4
80-100 Nm
58-72 ft.lbs.
70-80 Nm- 15-22 vNm

51-58 ftlbs. 11-16 ft
11 b1
OlAO620
Removal steps 35-4; Nm
25-33 ftlbs.
1. Drain plug
4. Left member
l * 5. Transfer assembly
6. Drive shaft
7. Exhaust pipe connection
8. Gasket
9. Oil return pipe connection NOTE
10. Gasket (I) Reverse the removal procedures to reinstall.
***+ll. Oilpan (2) +I) : Refer to “Service Points of Removal”.
12. Oil screen (3) H : Refer to “Service Points of Installation”.
13. Gasket (4) m : Non-reusable parts
SERVICE POINTS OF REMOVAL NOBHBAFal
5. REMOVAL OF TRANSFER ASSEMBLY

Refer to GROUP 21-Transfer.
(1) Remove the oil pan mounting bolts.
(2) Tap the special tool in between the cylinder block and
the oil pan.
Caution
Do not use a screwdriver, a chisel or a similar tool
when removing the oil pan.
(3) Remove the oil pan by placing a brass bar at the correct
of the special tool and then tapping with a hammer.
ENGINE <2.0L DOHC Engine> - Oil Pan and Oil Screen 9-89
INSPECTION &SHOW
l Check the oil pan for damage and cracks. Replace if faulty.
l Check the oil screen for clogging; damage and cracks.
Replace if faulty.
SERVICE POINTS OF INSTALLATION NOSHDASa

(1) Use a wire brush or other tool to scrape clean all gasket
surfaces of the cylinder block and oil pan so that all
loose material is removed.
(2) Gasket surfaces must be free of oil and dirt.
(3) Apply the specified sealant around the gasket surface

of the oil pan as specified in illustration.
Specified sealant: MITSUBISHI GENUINE PART
No. MD9971 10 or equivalent
NOTE
Sealant The sealant should be applied in a continuous head
approximately 4 mm (.I 6 in.) in diameter.
Groove ole of bolt

0180052
(4) Assemble oil pan to cylinder block within 15 minutes

after applying the sealant.
Caution
After installing the oil pan, wait at least 30 minutes
before starting the engine.
9-90 ENGINE <2.0L DOHC Engine> - Cylinder Head Gasket
CYLINDER HEAD GASKET NOSJA-S

2.5-3.5 N m 1 9 3 4 K
2-3 ft.lbs.
REIVIOVAL AND INSTALLATION \ I i-6
*Eliminating Fuel Pressure in Fuel 20
Line
(Refer to GROUP 14-Service Ad- 1 \
justment Procedures.)
eDraining of Engine Coolant
ment Procedures.)
,,vs
4-6 Nm ’
/ \ 05ADl90
I 28
I
29
36’ /w ,= 19. Center cover
3i 38 OlAO5.69
20. Connection for spark plug cable assembly
21. Connection for air intake hose (Turbo)
Removal steps 22. Connection for breather hose (Turbo)
l 1. Connection for accelerator cable or 23. Air intake hose
throttle cable 24. Connection for breather hose
2. Connection for accelerator cable (Auto- +e l 25. Connection for fuel high pressure hose
cruise control) 26. O-ring
3. Connection for oxygen sensor 27. Connection for vacuum hoses
temperature sensor 29. Connection for water by-pass hose
5. Connection for engine coolant 30. Connection for PCV hose
temperature gauge unit 31. Connection for vacuum hose (Turbo)
6. Connection for engine coolant 32. Connection for water hose (Turbo)
33. Eye-bolt (Turbo)
7. Connection for crank angle sensor 34. Gasket (Turbo)
8. Connection for TPS 35. Connection for oil pipe (Turbo)
ISC and idle switch 36. Connection for vacuum hoses (Turbo)
10. Connection for fuel injector 37. Connection for fuel return hose
38. Connection for brake booster vacuum
12. Connection for power transistor hose A
13. Connection for knock sensor (Turbo)
14. Connection for EGR temperature sensor NOTE
(California vehicles only) (1) Reverse the removal procedures to reinstall.
15. Connection for ground cable (2) +I) : Refer to “Service Points of Removal”.
(3) ~~ : Refer to “Service Points of Installation”.
+e l + 17. Connection for radiator upper hose (4) m : Non-reusable parts
ENGINE <2.0L DOHC Engine> - Cvlinder Head Gasket 9-91
2.5-3.5 Nm
2-3 ft.lbs. Post-installation Operation
-_ @Replenishing of Engine Coolant
I ment Procedures.)
*Engine Adjustment
(Refer to P.9-74.)
55-65 Nm
40-47 ftJbs.27
So-100 Nm
65-72 ft.lbs.
/
‘L- \
25-30 Nm
9
25-30 Nm
18-22 ft.lbs.
46
45m
18-22 ft.lbs.
m43
\
OlA0567
480
<Non-Turbo>
30-40 Nm
22-26 ft.lbs. 4* +4 39. Timing belt
<Turbo> l + 40. Rocker cover
40-60 Nm +441. Semi-circular packing
29-43 ft.lbs. 42. Self locking nuts
43. Gasket (Non-Turbo)
44. Heat protector (Turbo)
45. Gasket (Turbo)
22-29 ft.lbs. 46. Ring (Turbo)
- 4* +4 47. Cylinder head assembly
+4 48. Cylinder head gasket
NOTE
(3) ++ : Refer to “Service Points of installation”
9-92 ENGINE <2.0L DOHC Engine> - Cylinder Head Gasket
SERVICE POINTS OF REMOVAL NOSJSAP

17. REMOVAL OF RADIATOR UPPER HOSE F-is
Make mating marks on the radiator hose and hose clamp,
and then disconnect the radiator hose.
04A0090
25. DISCONNECTION OF HIGH PRESSURE FUEL HOSE

Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual ljressure
in the fuel pipe line.
For information concerning the bleeding of the residual
pressure, refer to GROUP 14-Service Adjustment Proce-
dures.
Refer to P.9-98.
47. REMOVAL OF CYLINDER HEAD ASSEMBLY
Using the special tool, loosen the bolts in the order shown
in the figure (in 2 or 3 cycles) and remove. Then remove the
cylinder head assembly. A
Front of engine *
Intake side
r
0 0 0
6 9 7
10 5
\
Exhaust side
ENGINE <2.0L DOHC Engine> - Cylinder Head Gasket 9-93
SERVICE POINTS OF INSTALLATION NOSJDDls
48. INSTALLATION OF CYLINDER HEAD GASKET

(1) Use a scraper to clean the gasket surface of the cylinder
block.
Caution
cylinder, or into coolant passages or oil passages.
(2) Make sure that the gasket has the proper identification
mark for the engine.
(3) Lay the cylinder head gasket on the cylinder block with
the identification mark at the front top.
47. INSTALLATION OF CYLINDER HEAD ASSEMBLY
(1) Use a scraper to clean the gasket surface of the cylinder
head assembly.
Caution
DlADD3f coolant passages or oil passages.
(2) Using the special tool and a torque wrench, tighten the
bolts to the specified torque in the order shown in the
figure. (in two or three cycles)
Caution
Install the head bolt washers as shown in the
diagram.
Front of engine+
Exhaust side
OlR0391
41. APPLICATION OF SEALANT TO SEMI-CIRCULAR PACK-

ING
Apply a coating of the specified sealant to the semi-circular
packing and the cylinder head to top surfaces.
lent
Cylinder he/d -Ani-circular

packing
9-94 ENGINE <2.0L DOHC Engine> - Cvlinder Head Gasket
40. INSTALLATION OF ROCKER COVER

Apply a coating of the specified sealant where shown in$e
figure, and then install the rocker cover to the cylinder Head
assembly.
lent
olAoo41
39. INSTALLATION AND ADJUSTMENT OF TIMING BELT

Refer to P.9-104.
25. CONNECTION OF FUEL HIGH PRESSURE HOSE

Delivery pipe
When connecting the fuel high-pressure hose to the
/
delivery pipe, apply a coating of gasoline to the hose union,
and insert so that the O-ring is not damaged.
High pressure b-ring

hose D3AOQ79
17. INSTALLATION OF RADIATOR UPPER HOSE

Align the mating marks (of the radiator hose and hose
clamp), and then, while applying force in the direction of the
arrow in the illustration, set the hose clamp to the trace
marks (on the hose) remaining from the prior connection.
Caution
Be sure to install the hose clamp at the trace marks (on
the hose) remaining from the prior connection.
04AOD98

ENGINE <2.0L DOHC Engine> - Timing Belt
TIMING BELT
50-65“Nm
REMOVAL AND INSTALLATION 50-65 Nm 36-47 ft:lbs.
36-47 ft.lbs.
*Removal of Under Cover I 30-
22-
60-80 Nm
WA0581
18. Rocker cover

lo-i2 Nm 19. Semi-circular packing
20-3\0 Nm 7-9 ftlbs. 20. Plug rubber
14-22 ftlbs. 2 1. Auto tensioner
22. Timing belt
23. Tensioner pulley
24. Tensioner arm
Removal steps 25. Idle oullev
26. Camshaft sprocket
1. Clamp for pressure hose (power steering) 27. Oil pump sprocket
2. Bracket 28. Crankshaft sprocket bolt
l * 3. Engine mount bracket 29. Special wastier
4. Clamp of return pipe (power steering) 30. Crankshaft sprocket
4* 5. Drive belt (alternator) 31. Flange
6. Drive belt (power steering) 32. Tensioner “B”
7. Tensioner pulley bracket 33. Timing belt “B”
8. Drive belt (air conditioner) 34. Silent shaft sprocket
9. Water pump pulley 35. Spacer
10. Water pump pulley (power steering) 36. Crankshaft sprocket “B”
11. Crankshaft pulley 37. Left engine support bracket
12. Timing belt front upper cover 38. Timing belt rear right cover
13. Timing belt front lower cover 39. Timing belt rear left cover (upper)
14. Center cover 40. Timing belt rear left cover (lower)
15. Breather hose
16. PCV hose NOTE
17. Connection for spark plug cables 4+ : Refer to “Service Points of Installation”.
9-96 ENGINE <2.0L DOHC Engine> - Timing Belt
Iv- IL 1’1111
7-9 ftlbs.
116 \
/
18 43-49
-_ - - Nm
-. . .
$0
30-42 Nm
22-30 ftlbs.
j2 \ 36
33
\
15-22 Nm
11-16 ftlbs.
z/
I \h \
\
-a ma .I~.. OIAOS83
20-27 Nm 110-130t Nm
su--Du Nrn
cI, 36-43 ft.lbs.
14-20 f&.lbs. Ibs .,iJ
60-94 f . .
Installation steps
40. Timing belt rear left cover (lower)
39. Timing belt rear left cover (upper)
38. Timing belt rear right cover
37. Left engine support bracket
I)+ 36. Crankshaft sprocket “B”
l + 35. Spacer
34. Silent shaft sprocket
l + 33. Timing belt “B”
l 4 Adjustment of timing belt “B” tension
32. Tensioner “B” 14. Center cover
l + 31. Flange l + 13. Timing belt front lower cover
++ 30. Crankshaft sprocket e+ 12. Timing belt front upper cover
29. Special washer 11. Crankshaft pulley
28. Crankshaft sprocket bolt 10. Water pump pulley (power steering)
l + 27. Oil pump sprocket 9. Water pump pulley
l + 26. Camshaft sprocket l + 8. Drive belt (air conditioner)
25. Idle pulley 7. Tensioner pulley bracket
e+ 21. Auto tensioner I)+ 6. Drive belt (power steering)
24. Tensioner arm l + 5. Drive belt (alternator)
l 23. Tensioner pulley 4. Return pipe clamp bolt (power steering)
l + 22. Timing belt 3. Engine mount bracket
l 4 Adjustment of timing belt tension 2. Bracket
20. Plug rubber 1. Clamp for pressure hose (power steering)
l + 19. Semi-circular packing
l 4 18. Rocker cover
17. Connection for spark plug cables
16. PCV hose NOTE
15. Breather hose +4 : Refer to “Service Points of Installation”.
ENGINE <2.0L DOHC Engine> - Timing Belt 9-97
SERVICE POINTS OF REMOVAL -a
-- 3. REMOVAL OF ENGINE MOUNT BRACKET
(1) With a wooden block placed against the oil pan part of
the engine, jack up the vehicle.
Caution
Jack up gently, so as not to apply a load to the
various parts.
(2) Remove the engine mount bracket,
5. REMOVAL OF DRIVE BELT (ALTERNATOR)

Before removing the drive belt, loosen the water pump
pulley mounting bolts.
Exhaust Intake cam-
1
r
21. REMOVAL OF AUTO TENSIONER
marks so as to bring the No. 1 cylinder to compression
top-dead-centre position.
At this time the timing marks of the camshaft sprocket
and the upper surface of the cylinder head should
coincide, and the dowel pin of the camshaft sprocket
should be at the upper side.
Caution
The crankshaft must always be rotated clockwise.
(2‘) Remove the auto tensioner.
Crankshaft
sproket sprockek
Olhw51
Make a mark on the back of the timing belt indicating the ~
Caution
Water or oil on the belt shorten its life drastically, so
26. REMOVAL OF CAMSHAFT SPROCKETS
(1) Using a wrench, hold the camshaft at its hexagon
(between the No.2 and No.3 journals) and remove the
camshaft sprocket bolt.
Caution
Locking the camshaft sprocket with a tool damages
the sprocket.
(2) Remove the camshaft sprockets.
27. REMOVAL OF OIL PUMP SPROCKET

(1) Remove the plug on the side of the cylinder block.
in.)] to block the left silent shaft.
(3) Remove the oil pump sprocket nut.
(4) Remove the oil pump sprocket.
33. REMOVAL OF TIMING BELT “B”

Make a mark on the back of the timing belt indicating the
Caution
Water or oil on the belt shorten its life drastically, so ++
INSPECTION WSKCAC
- TIMING BELTS
The timing belts must be checked closely. Should the following
defects be evident, replace the belt with a new one.
\ (1) Hardened back surface rubber
Glossy, non-elastic, and so hard that no mark is produced
even when scratched by a fingernai.1.
8
ooo 00
Q+i!il
(2) Cracked back surface rubber.

(3) Cracked or separated canvas.
(4) Cracked tooth bottom.
Crack (5) Cracked side.
rack
7EN207
(6) Abnormal wear on side.

NOTE
Normal belt should have clear-cut sides as if cut by a sharp
Separation
knife.
Rounded belt side
Abnormal wear
(fluffy canvas fiber) 7EN208
J
(7) Abnormal wear on teeth.

Initial stage:
Rubber
exposed Canvas on load side tooth flank worn (Fluffy canvas
fibers, rubber gone and color changed to white, and
unclear canvas texture)
Tooth missing and Final stage:
canvas fiber exoosed Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
(8) Missing tooth.
7EN209
TENSIONER PULLEY AND IDLER PULLEY

(1) Turn the pulleys to check for possible binding, excessive
play, and unusual noise. Replace the pulley if any of these
defects is evident.
(2) Replace if there is a grease leak.
6EN0159
-
AUTO TENSIONER
(1) Check the auto tensioner for possible leaks and replace as *
necessary.
(2) Check the rod end for wear or damage and replace as
necessary.
6EN0280 J
(3) Measure the rod protrusion. If it is out of specification,

12 mm replace the auto tensioner.
(.47 in.)
Standard value: 12 mm (.47 in.)
6EN0161
(4) Using a vise with soft jaws push in the auto tensioner rod. If
the rod can be easily retracted, replace the auto tensioner.
You should feel a fair amount of resistance when pushing
the rod in. ,J-
Caution
1. Clamp the auto tensioner in the vise so it maintains ’
a level position.
2. If the plug at the bottom of the auto tensioner

protrudes, surround it with a plain washer as
illustrated to prevent the plug from being in direct
contact with the vise.
Plug
6EN0281
SERVICE POINTS OF INSTALLATION msmm

Crankshaft
sprocket “B 36. INSTALLATlON OF CRANKSHAFT SPROCKET “B”
Install the crankshaft sprocket “B” as shown while paying
attention to its direction.
i;4
Crankshaft 6EN304
ENGINE <2.0L DOHC Engine> - Timinn Belt
Spacer
6s
(1) Apply a thin coat of engine oil to the outer circumfer-
il seal ence of the spacer.
(2) Install the spacer with the chamfered end facing the oil
seal.
NOTE
If the spacer is installed adversely, the oil seal may be
damaged, resulting in the oil leaks.
Chahfered 6EN009
Silent shaft 33. INSTALLATION OF TIMING BELT “B”

n sprocket I (1) Ensure that crankshaft sprocket “B” timing mark and
the silent shaft sprocket timing mark are aligned.
(2) Fit timing belt “B” over crankshaft sprocket “B” and
the silent shaft sprocket. Ensure that there is no slack in
Timing
mark the belt.
Crankshaft ) ~
sprocket “6”
. ADJUSTMENT OF TIMING BELT “B” TENSION

(1) Temporarily fix the timing belt “B” tensioner such that
Center of
the center of the tensioner pulley is to the left and
tensioner above the center of the installation bolt, and temporarily
pulley attach the tensioner pulley so that the flange is toward
the front of the engine.
Center of
installation bolt
(2) Holding the timing belt “B” tensioner up with your

finger in the direction of the arrow, place pressure on
the timing belt so that the tension side of the belt is
taut. Now tighten the bolt to fix the tensioner.
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension on the belt.
(3) To ensure that the tension is correct, depress the belt

(point A) with a finger. If not, adjust.
installation bolt -
S-102 ENGINE <2.0L DOHC Engine> - Timing Belt
Crankshaft 31. INSTALLATION OF FLANGE

syocket “ B ” Install the flange in correct direction as shown.
Caution
Pay special attention to the direction of the flange. If it
is installed in the wrong direction, a broken timiiig ‘belt
could result.
30. INSTALLATION OF CRANKSHAFT SPROCKET
Install the crankshaft sprocket in the correct direction as
Crankshaft drankshaft 6fN272 shown.
sprocket
Caution
Pay special attention to the direction of the flange. If it
is installed in the wrong direction, a broken timing belt
could result.
27. INSTALLATION OF OIL PUMP SPROCKET

in.) shaft] through the plug hole on the left side of
cylinder block to block the left silent shaft.
(2) Install the oil pump sprocket.
(3) Tighten the nut to the specified torque.
6EN I12
26. INSTALLATION OF CAMSHAFT SPROCKETS

Using a wrench, hold the camshaft at its hexagon (between
the No.2 and No. 3 journals) and tighten the bolt to
specification.
Caution
Locking the camshaft sprocket with a tool damages the
sprocket.
ENGINE <2.0L DOHC Engine> - Timing Belt s-103
21. INSTALLATION OF AUTO TENSIONER
(1) If the auto tensioner rod is in its fully extended position,
reset it as follows.
@ Keep the au ot t ensioner level and, in that position,
clamp it in the vise with soft jaws.
If the plug at the bottom of the auto tensioner

protrudes, surround it with a plain washer as
illustrated to prevent the plug from being in direct
contact with the vise.
Plug
6EN0281
@I Push in the rod little by little with the vise until the
set hole @ in the rod is aligned with that @I in the
cylinder.
--
@ Insert a wire [1.4 mm (055 in.) in diameter] into the

set holes.
@I Unclamp the auto tensioner from the vise.
(2) Install the auto tensioner.
Caution
Leave the wire installed in the auto tensioner.
I 23. INSTALLATION OF TENSIONER PULLEY

Center bolt
(1) Install the tensioner pulley onto the tensioner arm.
(2) Locate the pinhole in the tensioner pulley shaft to the
left of the center bolt. Then, tighten the center bolt
finger-tight.
Caution
Leave the wire installed in the auto tensioner.
6EN0283
ENGINE <2.0L DOHC Engine> - Timing Belt
22. INSTALLATION OF TIMING BELT
Dowel Camshaft sprocket (1) Turn the two sprockets so that their dowel pind arti -
located on top. Then, align the timing marks facing each *
other with the top surface of the cylinder head. When,
you let go of the exhaust camshaft sprocket, it will
rotate one tooth in the counterclockwise direction. This
should be taken into account when installing the timing
belt on the sprockets.
Timing mark
6EN0264
NOTE
The same camshaft sprocket is used for the intake and
exhaust camshafts and is provided with two timing
marks. When the sprocket is mounted on the exhaust
camshaft, use the timing mark on the right with the *
dowel pin hole on top. For the intake camshaft -
sprocket, use the one on the left with the dowel pin
hole on top.
Tim
mar
(2) Align the crankshaft sprocket timing mark.

(3) Align the oil pump sprocket timing mark.
(4) Remove the plug on the cylinder block and insert a

Phillips screwdriver [shank diameter 8 mm (.31 in.)]
through the hole.
If it can be inserted as deep as 60 mm (2.4 in.) or more,
the timing marks are correctly aligned. If the inserted
depth is only 20-25 mm (.8-l .O in.), turn the oil pump
sprocket one turn and realign timing marks. Then check
to ensure that the screwdriver can be inserted 60 mm
(2.4 in.) or more. Keep the screwdriver inserted until the ,+
installation of the timing belt is finished. .
NOTE
Step (4) is performed to ensure that the oil pump
sprocket is correctly positioned with reference to the
silent shafts.
ENGINE <2.0L DOHC Engine> - Timing Belt 9405
(5) Thread the timing belt over the intake side camshaft
sprocket and fix it an indicated position by a clip.
(6) Thread the timing belt over the exhaust side sprocket,
aligning the timing marks with the cylinder head top
surface using two wrenches.
(7) Fix the belt at indicated position by a clip.
(8) Thread the timing belt over the idler pulley, the oil pump
sprocket, the crankshaft sprocket and the tension
pulley in the order shown.
(9) Remove the two clips.
(1O)Lift up the tensioner pulley in the direction of arrow and

tighten the center bolt.
(11)Check to see that all timing marks are lined up.
(12)Remove the screwdriver inserted in step (4) and fit the
plug.
(13)Give the crankshaft a quarter counterclockwise turn.
Then, turn it clockwise until the timing marks are lined
up again.
. ADJUSTMENT OF TIMING BELT TENSION
(1) After turning the crankshaft l/4 turn counterclockwise, .5;;
turn it clockwise to move the No. 1 cylinder to top dead
center.
(2) Loosen the center bolt, and then, as shown in the
illustration, attach the special tool and a torque wrench
and apply a torque of 2.6-2.8 Nm (1.88-2.03 ft.lbs.).
If the body interferes with the special tool and the
torque wrench, use a jack to slightly raise the engine
assembly.
NOTE
Use a torque wrench that is capable of measurement
within a range of O-3 Nm (O-2.2 ft.lbs.).
(3) Holding the tensioner pulley with the special tool and
torque wrench, tighten the center bolt to specification.
(4) Screw the special tool into the engine left support
bracket until its end makes contact with the tensioner
arm. At that point, screw the special tool in some more
and then remove the set wire attached to the auto
tensioner.
(5) Remove the special tool.
(6) Rotate the crankshaft two complete turns clockwise

and leave it as is for about 15 minutes. Then, measure
the auto tensioner protrusion “A” (distance between
the tensioner arm and auto tensioner body) to ensure ,.+
that it is up to specification.
If it is out of specification, repeat steps (6) through (1)
until the specified value is obtained.
(7) If the clearance between the tensioner arm and the

auto tensioner body cannot be measured (when the
engine is being mounted, etc.), the following proce-
dures can be used to substitute for the ordinan/ method
of measurement.
@ Screw in the special tool until it contacts the
tensioner arm.
@ From that point of contact, further screw in the
special tool, screwing it in until the push rod of the
auto tensioner body is caused to move backward
and the tensioner arm contacts the auto tensioner
body.
Check to be sure that the amount that the special
tool has been screwed in (when the push rod
moves backward) is the standard value.
Standard value: 2.5-3 turns
(8) Install the rubber plug to the timing belt rear cover.
19. APPLICATION OF SEALANT ON SEMI-CIRCULAR

PACKING
Apply sealant
Apply sealant on the periphery of the semi-circular packing.
lent
Cylinder head
3EN0044
18. APPLICATION OF SEALANT ON ROCKER COVER

Apply sealant to the areas indicated in the illustration.
lent
APPLY
sealant
10 mm 10 mm
(.4 in.) (.4 in.)
6EN0286
9-l 08 ENGINE <2.0L DOHC Engine> - Timing Belt
13. INSTALLATION OF TIMING BELT LOWER COVER/

12. TIMING BELT UPPER COVER F-s
The dimensions of the installation bolts for the timing
covers differ according to the installation location, so be
sure not to install the bolts in the incorrect locations.
.hread diameter
\: 6 x 16 (24 x .63) OlAOO45

I: 6 x 18 (.24x .70)
‘. 6 x 25 (.24 x .98)
;. 6x28 (.24~1.10) m m ( i n , )
8. TENSION ADJUSTMENT OF THE AIR CONDITIONER

COMPRESSOR DRIVE BELT
6. DEFLECTION ADJUSTMENT OF POWER STEERING OIL .++
PUMP DRIVE BELT
5. TENSION ADJUSTMENT OF THE ALTERNATOR DRIVE
BELT
Refer to GROUP 7-Maintenance Service.
ENGINE <2.0L DOHC Engine> - Camshaft and Rocker Arm 9-l 09
CAMSHAFT AND ROCKER ARM No9LE-B
- DISASSEMBLY AND REASSEMBLY 3
19-21 Nm 8,
14-15 ftlbs., 9 IQ&”
80-100 Nm
58-72 ftlbs.
IO-13 Nm
,11 7-9 ftlbs.
6EN0467
++ 7. Bearing cap No. 2

+a 8. Bearing cap No. 4
~~ 9. Beanng cap No. 3
l * 1;: kz$&;;m
12. Lash adjuster
Disassembly steps 13. Oil delivery body
r)+ 1. Crank angle sensor
+* l + 2. Camshaft sprocket NOTE
l + 3. Bearing cap rear (I) Reverse the disassembly procedures to reassemble.
*4 4. Bearing cap front (2) 4e : Refer to “Service Points of Disassembly”.
l 4 5. Camshaft oil seal (3) l a : Refer to “Service Points of Reassembly”.
l * 6. Bearing cap No. 5 (4) m : Non-reusable parts
SERVICE POINTS OF DISASSEMBLY NOSLBDD
2. REMOVAL OF CAMSHAFT SPROCKET

(1) Using a wrench, hold the camshaft at its hexagon
(between the No.2 and No.3 journals) and remove the
camshaft sprocket bolt.
Caution
Locking the camshaft sprocket with a tool damages
the sprocket.
(2) Remove the camshaft sprockets.
9-110 ENGINE <2.0L DOHC Engine> - Camshaft and Rocker Arm
I
INSPECTION
CAMSHAFT h
(1) Visually check the camshaft journal surfaces and replace if _
damage or seizure is evident.
If the journal is seized, check the cylinder head for possible
damage. Check also for clogged oil holes in the cylinder
head.
I 6EN0183
(2) Check cams for excessive wear and damage and replace if
defects are evident. Measure the cam height and replace if
the limit is not reached.
Standard value:
Intake
<Non-Turbo, Turbo-M/T> 35493mm (1.3974 in.)
<Turbo-A/T> 35.200mm (1.3858 in.)
Exhaust
<Non-Turbo, Turbo-A/T> 35.200mm (1.3858 in.)
<Turbo-M/T> 35.493mm (1.3974 in.)
I 6EN0184
Limit:
I
Intake
<Non-Turbo, Turbo-M/T> 34.993mm (1.3777 in.)
<Turbo-A/T> 34.700mm (1.3661 in.)
Exhaust
<Non-Turbo, Turbo-A/T> 34.700mm (1.3661 in.) /“4
<Turbo-M/T> 35.993mm (1.3777 in.)
ROCKER ARM
(1) Visually check the roller and replace if dent, damage, or
seizure is evident.
(2) Check the roller for smooth rotation. Replace if it binds or
I 6EN0185 there is an excessive play.
(3) Check the valve contact surface for possible damage or
, I
seizure and replace as necessary.
+
Front of engine (Timing belt side)
SERVICE POINTS OF REASSEMBLY NOSLGAB
10. INSTALLATION OF CAMSHAFT
WIB’ S’it
(1) Apply engine oil to journals and cams of the camshafts.
(2) Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crank angle sensor.
’ Intake side (3) Make also sure that the dowel pins on the camshaft
camshaft 6E NO289 sprocket end are located on the top.
9./8./7./6./4./3. INSTALLATION OF BEARING CAPS
(1) Bearing cap Nos.2 to 5 are of the same shape. At
installation, check with the markings on the caps of cap
number and intake/exhaust identification symbol. Only
Cap number “I” or “E” is stamped on No. 1 bearing cap. 4
Symbol I : For Intake camshaft side ,
identifying
intake or E: For Exhaust camshaft side
exhaust
6EN6464
I
ENGINE <2.0L DOHC Engine> - Camshaft and Rocker Arm 9-111
_ Front of engine (Timing belt side) (2) Tighten the bearing caps in the order shown two to
three times by torquing progressively.
Tighten to specification in the final sequence.
(3) Check to be sure that the rocker arm is correctly placed
on the lash adjuster and valve stem end.
0 Co@
6EN0192
MD998306 Oil seal 5. INSTALLATION OF CAMSHAFT OIL SEAL

(1) Install the special tool, Guide, on the camshaft.
(2) Apply oil to the oil seal and insert the seal along the
Guide until it contacts the cylinder head.
(3) Using the special tool, Installer, press-fit the oil seal into
the cylinder head.
Y-II- 6ENI0194
2. INSTALLATION OF CAMSHAFT SPROCKET

Using a wrench hold the camshaft at its hexagon (between
the No.2 and No.3 journals) and tighten the bolt to
specification.
Caution
Locking the camshaft sprocket with a tool damages the
sprocket.
1. INSTALLATION OF CRANK ANGLE SENSOR

(1) Locate the dowel pin on the sprocket side of the intake
camshaft at top.
6EN030’
1 (2) Align the punch mark on the crank angle sensor housing
with the notch in plate.
NOTE
The crank angle sensor can be installed even when the
punch mark is positioned opposite the notch; however,
the position results in incorrect fuel injection and
ignition timings.
(3) Install the crank angle sensor on the cylinder head.
9-112 ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve
CYLINDER HEAD AND VALVE

DISASSEMBLY AND REASSEMBLY Newlie6
Disassembly steps
Cylinder head bolt
Washer
r$!$zr head
Retainer lock
Valve spring retainer
Valve spring
Intake valve
Retainer lock
Valve spring retainer
Valve spring
Exhaust valve
Valve stem seal
Valve spring seat 6E NO196
Valve stem seal
Valve spring seat
Intake valve guide !??everse the disassembly procedures to reassemble.
Exhaust valve guide (2) +e : Refer to “Service Points of Disassembly”.
Intake valve seat (3) H : Refer to “Service Points of Reassembly”.
Exhaust valve seat (4) m : Non-reusable parts
ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve 9-l 13
SERVICE POINTS OF DISASSEMBLY NOBPFAti
1. REMOVAL OF CYLINDER HEAD BOLTS

(1) Using the special tool, remove the cylinder head bolts in
sequence shown in figure.
(2) Loosen the cylinder head bolts in the order shown.

a Front of engine (Timing belt side)
Loosen bolts evenly little by little, taking several steps.
6EN0211
8. REMOVAL OF INTAKE VALVE/12. EXHAUST VALVE

(1) Using the valve spring compressor, compress the
spring and remove the retainer lock.
(2) Remove the spring retainer, valve spring, spring seat,
and valve.
. (3) Keep removed parts in order according to the cylinder
number and intake/exhaust.
13./15. REMOVAL OF VALVE STEM SEALS

To remove the valve stem seal, use pliers.
Caution
Do not reuse the stem seals.
INSPECTION
CYLINDER HEAD
(1) Before cleaning the cylinder head, be sure to check for
possible coolant or gas leak, damage, and cracks.
(2) Completely remove oil, scale, sealant, and carbon deposits.
After the oil passages have been flushed, blow air into the
passages to ensure that they are not plugged.
9-114 ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve
(3) Using a straight edge and feeler gauge, check the cylinder
head bottom surface for flatness. If it warps excessively
correct by grinding within the allowable limit.
Bottom surface distortion
Standard value: Within 0.05 mm (.0020 in.)
Limit: ‘0.2 mm (.dO8 in.)
Grinding limit: 0 . 2 mm (.008 iA.)-
Cylinder head height (when new):
132.0 mm (5.197 in.)
Caution
The total thickness of the stock allowed to be removed
from the cylinder head and mating cylinder block is 0.2
mm (.008 in.) at maximum.
VALVE NOSPGAE
(1) Check the valve stem for wear (ridge wear).

(2) Check the valve stem end face for wear and dents.
Ridge
wear
1 EN034
(3) Check the valve seat for proper contact with the valve set.
If it is not concentric, correct the valve seat.
(4) If the margin is out of the limit, replace the valve.
Contact with Standard value:
valve seat Intake 1.0 mm (.040 in.)
(to be at center Exhaust 1.5 mm (.059 in.)
Limit:
Intake 0.7 mm 1.028 in.)
Exhaust 1.0 mm (.040 in.)
6EN020
VALVE SPRING NOSPGBC

Measure the free height of the spring and replace if it is out
of the limit.
Standard value: 48.3 mm (1.902 in.)
Limit: 47.3 mm (1.862 in.)
Free Check the spring for squareness and replace if the limit is
height
exceeded.
I
Standard value: Less than 1.5’
1 EN035
-
Limit: 4”
ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve 9-115
1 NOSPGCC
VALVE GUIDE
Measure the clearance between the valve guide and valve
stem and, if the clearance exceeds the limit, replace the valve
guide or valve, or both.
Standard value:
Intake 0.02-0.047 mm (.OOOS-.0019 in.)
Exhaust 0.05-0.085 mm (.002-.0033 in.)
Limit:
Intake 0.10 mm (.0040 in.)
Ghde I.D. Guide O.D. 1 EN298 Exhaust 0.15 mm (.0059 in.)
SERVICE POINTS OF REASSEMBLY NoaPKDEa

MD998737 15. / 13. INSTALLATION OF VALVE STEM SEAL
Valve Valve (1) Install the valve spring seat.
spring * stem (2) Using the special tool, install a new stem seal to the
seat seal
:: valve guide.
\ iIril Caution
1. Do not reuse the valve stem seal.
2. Use the special tool to install the valve stem
seal. Improper Jnstallation can be a cause of
leakage of oil down into the cylinder.
9. /5. INSTALLATION OF RETAINER LOCK

Spring (1) Install the valve spring so that its end with identification
color is positioned on the rocker arm end.
(2) Using the valve spring compressor, compress the valve

spring and insert the retainer lock into position.
Caution
If the valve spring is compressed excessively, the
lower end of the retainer contacts the ‘stem seal,
damaging the stem seal.
9416 ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve
I I 1. INSTALLATION OF CYLINDER HEAD BOLTS
(1) Using the special tool, tighten the cylinder head bolts.
(2) Tighten the cylinder head bolts in the sequence shown.

G Front of engine (Timing belt side) Each bolt should be tightened in two to three steps,
torquing progressively. Tighten to specified torque in
the final sequence.
ENGINE <2.0L DOHC Engine> - Front Case, Oil Pump and Silent Shaft 9-117
FRONT CASE, OIL PUMP AND SILENT SHAFT 32

I
NOSRF-B
40-45 Nm
29-33 ft.lbs.
\
11-13 ft.lbs.
LO
8-12 Nm \
6-9 ft.lbs.
\ 7 15-22 Nm -
11-16 ft.lbs.,
15-22 Nm
11-16 ft.lbs.
\ ‘ 1 6EN0468
Disassembly steps
/
35-45 Nm
I. Drain pluo 25-33 ft.lbs.
2. Gasket -
l + 3. Oil filter l 4 23. Oil seal
4. Oil cooler bolt (Turbo) l + 24. Silent shaft oil seal
~~ 5. Oil cooler (Turbo) l + 25. Crankshaft front oil seal
6. Oil pressure switch 26. Oil pump cover
7. Harness assembly l * 27. Oil pump driven gear
8. Oil pressure gauge unit e+ 28. Oil pump drive gear
9. Oil pan 29. Left silent shaft
10. Oil screen 30. Right silent shaft
11. Gasket W W 31. Silent shaft front bearings
12. Oil filter bracket W W 32. Right silent shaft rear bearing
13. Gasket ~~ ~~ 33. Left silent shaft rear bearing
14. Relief plug 34. Check valve (Turbo)
15. Gasket 35. Gasket (Turbo)
16. Relief spring l + 36. Oil jet (Turbo)
17. Relief plunger 37. Gasket (Turbo)
l I) W 18. Plug cap - NOTE
19. O-ring (1) Reverse the disassembly procedures to reassemble.
+e I)+ 20. Driven gear bolt (2) 4I) : Refer to “Service Points of Disassembly”.
I)+ 21. Front case (3) ~~ : Refer to “Service Points of Reassembly”.
22. Gasket (4) m : Non-reusable parts
9-118 ENGINE <2.0L DOHC Engine> - Front Case, Oil Pump and Silent Shaft
SERVICE POINTS OF DISASSEMBLY NOIROA~U

6. REMOVAL OF OIL PRESSURE SWITCH
(1) Remove the oil pressure switch terminals.
(2) Using the special tool, remove the oil pressure switch.
Caution
Since sealant is coated on the thread area, be
careful not to break it.
7LUOOO5
I _ MD998727 _ MD998727 9. REMOVAL OF OIL PAN

(1) Remove the all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
oil pan.
NOTE
Never use a screwdriver or chisel, instead of the special
tool, as a deformed oil pan flange will result, resulting in
oil leakage.
18. REMOVAL OF PLUG CAP

Using the special tool, remove the plug cap.
20. REMOVAL OF DRIVEN GEAR BOLT

(1) Remove the plug on the side of cylinder block.
in.)] into the plug hold to block the silent shaft.
(3) Remove the driven gear bolt that secures the oil pump
driven gear to the silent shaft.
ENGINE <2.0L DOHC Engine> - Front Case, Oil Puma and Silent Shaft 9419
31. REMOVAL OF SILENT SHAFT FRONT BEARINGS
Using the special tool, remove the right silent shaft front
bearing from the cylinder block.
NOTE
Be sure to remove the front bearing first.
If it has not been removed, the Rear Bearing Puller cannot
be used.
3EN041
32. REMOVAL OF RIGHT SILENT SHAFT REAR BEARING

Using the special tool, remove the right silent shaft rear
33. REMOVAL OF LEFT SILENT SHAFT REAR BEARING

Using the special tool, remove the left silent shaft rear
INSPECTION
FRONT CASE NOSRCJCl
(1) Check oil holes for clogging and clean if necessary.

(2) Check silent shaft front bearing section for wear, damage
and seizure. If there is anything wrong with the section,
replace the front case.
(3) Check the front case for cracks and other damage. Replade
cracked or damaged front case.
OIL SEAL NOSRCMAl
(1) Check the oil seal lip for wear and damage. Replace oil seal
if necessary.
(2) Check the oil seal lip for deterioration. Replace oil seal !if
necessary.
OIL PRESSURE SWITCH -1
(1) Connect a tester (ohm range) between the terminal and the
body and check for conductivity. If there is no conductivity,
replace the switch.
7LUOoo6
(2) Next insert a very fine wedge through the oil hole, pushing
it slightly. There should be no conductivity (resistance
should be infinite). If there is conductivity even when
wedge is pushed, replace the switch.
(3) Or, if there is no conductivity when a 50 kPa (71 psi)
pressure is placed through the oil hole, the switch is
Fine operating properly. Check at this time to see that there is
no air pressure leakage. If there is air pressure leakage, the
diaphragm is broken, and the switch should be replaced.
7LUOOO7
OIL COOLER BYPASS VALVE (Turbo) NaacNA

(1) Make sure that the valve moves smoothly.
(2) Ensure that the dimension L measures the standard value
under normal temperature and humidity. k
Dimension L: 34.5 mm (1.358 in.)

(3) The dimension must be the standard value when measured
after the valve has been dipped in 100°C (212°F) oil.
Dimension L: 40 mm (1.57 in.) or more
6LUO12
OIL PUMP NOBRCGG
(1) Assemble the oil pump gear to the front case and rotate it
to ensure smooth rotation with no looseness.
(2) Ensure that there is no ridge wear on the contact surface
between the front case and the gear surface of the oil
pump cover.
(3) With the drive and driven gears installed into the front case.
Standard value:
Drive gear 0.16-0.21 mm (.0063-.0083 in.)
Driven gear 0.13-0.18 mm (.0051-.0071 in.)
Limit:
Driven gear 0.25 mm (4098 in.)
(4) Check the side clearance.
Standard value:
Drive gear 0.08-0.14 mm (.0031-.0055 in.)
Driven gear 0.06-0.12 m m (.0024-.0047 in.)
Limit:
Driven gear 0.25 mm (.0098 in.)
I I 6LUOO13~
SILENT SHAFT NOBRUE
(1) Check oil holes for clogging.

(2) Check journal for seizure, damage, and contact with
bearing. If there is anything wrong with the journal, replace
silent shaft, bearing or front case assembly.
(3) Check the silent shaft oil clearance. If the clearance is
excessively due to wear, replace the silent shaft bearing,
silent shaft or front case assembly.
Standard value:
Front
DEN662
Right 0.020-0.061 mm (.0008-.0024 in.)
Left 0.050-0.091 mm (.0002-.0036 in.)
Rear
Right 0.020-0.054 mm (.0008-.0021 in.)
Left 0.042-0.083 mm (.0017-.0033 in.)
OIL JET, CHECK VALVE NOSRCOA

Engine oil b
(1) Check the oil jet and check valve for clogging.
(2) Check the oil jet for damage and deformation.
Oil jet
Check valve assembly
DLU015
SERVICE POINTS OF REASSEMBLY NOSRHAG
36. INSTALLATION OF OIL JET ;;;it

When installing the oil jet, make sure that the nozzle is in _
correct direction, that is, toward the piston.
Main gallery
<neck pi
Check valve
6LUO14
33. INSTALLATION OF LEFT SILENT SHAFT REAR BEAR-

ING
(1) Install the special (GUIDE PLATE) tool to the cylinder
block. k
(2) Apply engine oil to the rear bearing outer circumference 1
and bearing hole in cylinder block.
Left (3) Using the special tool, install the rear bearing.
rear
bearing NOTE
The left rear bearing has no oil holes.
6EN323
ENGINE <2.0L DOHC Engine> - Front Case, Oil Pump and Silent Shaft
32. INSTALLATION OF RIGHT SILENT SHAFT REAR BEAR-

-
ING
(1) Apply engine oil to outer surface of bearing.
(2) Using special tools, install right rear bearing. Make sure
that oil hole of bearing is aligned with oil hole of cylinder
block.
6EN388
6EN390
31. INSTALLATION OF SILENT SHAFT FRONT BEARINGS

(1) Using special tools, install front bearing.
6EN388
block 6EN391
(2) Make sure that oil hole of bearing is aligned with oil hole
of cylinder block.
Oil
6FN074
(3) Furthermore, make sure that clinch of bearing is in

upper most position.
Oil hole
6EN075 1
28. INSTALLATION OF DRIVE GEAR/27. DRIVEN GEAR

Coat the gear with plenty of engine oil, and align the two
timing marks.
25. INSTALLATION OF CRANKSHAFT FRONT OIL SEAL

Using the special tool, install the crankshaft front oil seal
into front case.
24./23. INSTALLATION OF OIL SEAL

Using a socket wrench, press-in the oil seal into front case.
6EN331j
21. INSTALLATION OF FRONT CASE

(1) Set the special tool on the front end of the crankshaft
and apply a thin coat of engine oil to the outer
circumference of the special tool to install the front
case.
(2) Install the front case assembly through a new front
case gasket and temporarily tighten the flange bolts
(other than those for tightening the filter bracket).
6E N026:
(3) Mount the oil filter bracket with oil filter bracket gasket.
Then, install the four bolts with washers.
(4) Tighten the bolts to specification.
NOTE
Bolts indicated by the * symbol should be tightened at a
torque of 27-34 Nm (20-25 ft.1b.s.).
20. INSTALLATION OF DRIVEN GEAR BOLT

(1) Insert a Phillips screwdriver into a hole in the left side of
the cylinder block to lock the silent shaft.
(2) Secure the oil pump driven gear onto the left silent
shaft by tightening the driven gear bolt to specified
torque.
18. INSTALLATION OF PLUG CAP

(1) Install a new O-ring to the groove of front case.
(2) Using the special tool, install the plug cap and tighten to
specified torque.

(1) Clean both mating surfaces of oil pan and cylinder +
block.
(2) Apply a 4 mm (.I 6 in.) wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
MITSUBISHI GENUINE PART No. MD9971 10 or
equivalent
(3) The oil pan should be installed in 15 minutes after the
6EN0213 application of sealant.
(4) Note the difference in bolt lengths at the location

w Crank pulley side
shown.
Oil pan
from lower side
8. INSTALLATION OF OIL PRESSURE SWITCH

(1) Coat sealant on the thread area, and using the special
tool, install the pressure switch.
lu
Specified sealant: MOPAR Part No.4318034 or
equivalent
Caution
1. Do not let sealant ooze out of the top of the
‘- Apply sealant thread area.
2. Do not overtighten the pressure switch.
7LUOOO0 (2) Install the oil pressure switch terminals.
5. INSTALLATION OF OIL COOLER
First insert the oil cooler projecting stopper in the oil filter
bracket groove and then tighten the oil cooler bolts.
6LUOO49 t
3. INSTALLATION OF OIL FILTER

Bracket side Wipe clean the mounting surface on the filter bracket.
-----Be Then, apply a thin coat of engine oil to filter O-ring and
tighten the oil filter by hand.
\ Caution -.
Apply oil
Never use a wrench to tighten the oil filter. -i
1 6LUO26
ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod
PISTON AND CONNECTING ROD NonlE-8

cIISASSEMBLY AND REASSEMBLY
disassembly steps f86 50-53 Nm

36-36 ftlbs. 6EN0216
1. Nut
+e l + 2. Connecting rod cap
3. Connecting rod bearing
e+ 4. Piston and connecting rod assembly
5. Connecting rod bearing
6. Bolt
+e ~~ 7. Piston ring No. 1
+e ++ 8. Piston ring No.2
l * 9. Oil ring NOTE
10. Piston pin (1) Reverse the disassembly procedures to reassemble
11. Piston (2) l e : Refer to “Service Points of Disassembly”.
12. Connecting rod (3) +4 : Refer to “Service Points of Reassembly”.
9-128 E N G I N E <2.0L DOHC Enaine> - Piston and Connectina Rod
SERVICE POINTS OF DISASSEMBLY NOSTFAC
2. REMOVAL OF CONNECTING ROD CAP

Mark the large end of the connecting rod with the cylinder
number for use during reassembly.
DEN050
7. REMOVAL OF NO. 1 PISTON RING /8. NO.2 PISTON

RING
Remove the piston rings with a piston expander.
6EN185 J
INSPECTION
PISTON NO@lCAF
Replace the piston if scratches or seizure is evident on its

surfaces (especially the thrust surface). Replace the piston if it
is cracked.
PISTON PIN
(1) Insert the piston pin into the piston pin hole with a thumb.
You should feel a slight resistance. Replace the piston pin if
it can be easily inserted or there is an excessive play.
(2) The piston and piston pin must be replaced as an assembly.
PISTON RING NOSTCBF
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check the clearance between the piston ring and ring
groove. If the limit is exceeded, replace the ring or piston,
or both.
9 5EN057
Limit: 0.1 mm (.004 in.)
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring, to
correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
No. 1 0.25-0.40 mm (.0098-.0157 in.)
No.2 0.20-0.35 mm (.0079-.0138 in.)
Oil 0.20-0.70 mm (.0079-.0276 in.)
Limit:
Piston ring ring gap No. 1, No.2 0.8 mm (.031 in.)
6EN037
Oil 1.0 mm (.039 in.)
ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod gi’1.29
CONNECTING ROD BEARING NWTCDD
(1) Visually check the bearing surface for uneven contact,

streaks, scratches, and seizure. Replace if defects are
evident. If streaks and seizure are excessive, check also the
crankshaft. If damage is present on the crankshaft, replace
crankshaft or regrind to undersize for reuse.
(2) Measure the connecting rod bearing I.D. and crankshaft pin
O.D. if the oil clearance exceeds the limit, replace bearing,
and crankshaft if necessary. Or, regrind the crankshaft to an
undersize and replace bearing with an undersize one.
Standard value: 0.02-0.05 mm (.0008-JO20 in.)
Limit: 0.1 mm (.004 in.)
NOTE
For oil clearance measuring method using the plastic
gauge, refer to the section CRANKSHAFT.
SERVICE POINTS OF REASSEMBLY NO9TGACa
9. INSTALLATION OF OIL RING

(1) Fit the oil ring spacer into’the piston ring groove.
NOTE
The side rails and spacer may be installed in either
direction.
6EN377
(2) Install the upper side rail.

Side rail gap To install the side rail, first fit one end of the rail into the
I piston groove, then press the remaining portion into
position by finger. See illustration.
Use of ring expander to expand the side rail end gap can
break the side rail, unlike other piston rings.
NOTE
Do not use piston ring expander when installing side
rail.
(3) Install the lower side rail in the same procedure as
L
1 EN062I described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.
9-130 ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod
8. INSTALLATION OF PISTON RING NO.217. PISTON
RING NO.1
Using a piston ring expander, fit the No.2 and then No. 1 n*t
piston ring into position.
NOTE
1. Note the difference in shape between No. 1 and No. 2
piston rings.
2. Install piston rings No. 1 and No. 2 with their side having
marks facing up (on the piston crown side).
\ ’ 7EN250
Non-Turbo Turbo
4. INSTALLATION OF PISTON AND CONNECTING ROD

Upper
(1) Liberally coat engine oil on the circumference of the
piston, piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and A
spacer) as shown in the figure.
(3) Rotate crankshaft so that crank pin is on center of
cylinder bore.
LC 3wer
No.2 ring gap
and spacer gap siae’ rail‘I
6 EN041
(4) Use suitable thread protectors on connecting rod bolts

tiefore inserting piston and connecting rod assembly
into cylinder block. Care must be taken not to nick crank
pin.
(5) Using a suitable piston ring compressor tool, install
piston and connecting rod assembly into cylinder block.
Caution
Insert the front mark (aryow) on the top of the
piston so it faces the erigine front (timing belt side).
2. INSTALLATION OF CONNECTING ROD CAP

(1) Mate the correct bearing cap with the correct connect-
ing rod by checking with the alignment marks marked
during disassembly. If a new connecting rod is used
der No. I;r.
which has no alignment mark, position the notches for
locking the bearing on the same side.
Notch
DEN057
ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod 9-131
(2) Check if the thrust clearance in the connecting rod big
end is correct.
Limit: 0.4 mm (.0157in.)
g-132 ENGINE <2.0L DOHC ‘Engine> - Crankshaft, Flywheel and Drive Plate
CRANKSHAFT, FLYWHEEL AND DRIVE PLATE

DISASSEMBLY AND REASSEMBLY NOBUE-B
1
5
lo-12 Nm 130-140 Nm
7-9 ft.lbs. I ‘94-101 ft.lbs.
FORWARD
130-140 Nm
IO-12 N/m 94-101 ft.lbs.
7-9 ft.lbs. I
47-51 ftlbs.
6ENO227
Disassembly steps
1. Flywheel (Manual transaxle)
2. Adapter plate Automatic
3. Drive plate transaxle
4. Crankshaft bushing
5. Rear plate
7. Oil seal case
8. Gasket
l + 9. Oil separator
l a 10. Oil seal
l + 11. Bearing cap NOTE
l + 12. Lower bearing (1) Reverse the disassembly procedures to reassemble.
13. Crankshaft (2) e+ : Refer to “Service Points of Reassembly”.
l + 14. Upper bearing (3) 0 : Non-reusable parts
ENGINE <2.0L DOHC Engine> - Crankshaft, Flywheel and Drive Plate,91133
INSPECTION NOSUHAD
CRANKSHAFT
(1) Check the crankshaft journals and pins for streaks and
seizure. Replace if necessary.
(2) Measure the journal O.D. and main bearing I.D. to obtain
the clearance between the two (oil clearance). If the
clearance exceeds the limit, replace the main bearing and,
if necessary, the crankshaft.
Standard value: 0.02-0.05 mm (.OOOS-.0020 in.)
Limit: 0.1 mm (.0040 in.)
Caution
A special surface treatment has been applied to
crankshaft. Do not machine it to undersize.
6EN0’228
\ 3EN056
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE

Plastic METHOD)
The crankshaft oil clearance can be measured easily by using a
plastic gauge, as follows:
(1) Remove oil and grease and any other foreign matters from
crankshaft journal and bearing inner surface.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width of
bearing and place it on journal in parallel with its axis.
6EN043
(4) Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
(5) Remove the bolts and gently remove the crankshaft
bearing cap.
.. (6) Measure the width of the smashed plastic gauge at its
widest section by using a scale printed on the plastic gauge
bag.
I
1 EN067
-
g-134 ENGINE <2.0L DOHC Engine> - Crankshaft, Flywheel and Drive Plate
CRANKSHAFT REAR OIL SEAL

(1) Check oil seal lip for wear and damage.
(2) Check rubber for deterioration or hardening.
(3) Check oil seal case for cracks and damage.
RING GEAR (Engine with a manual transaxle)

Check teeth of ring gear for wear and damage. If necessary,
replace the ring gear.
If the ring gear teeth are worn or damaged, also check the
starter motor pinion.
To remove the ring gear, strike the ring gear at several points
on its outer circumference. The ring gear cannot be removed if
it is heated.
To install the ring gear, heat the ring gear to 300°C (572°F) for
shrink fit.
3EN301
FLYWHEEL (Engine with a manual transaxle)

(1) Check the clutch disc friction surface for ridge wear,
streaks, and seizure. If necessary, replace flywheel.
(2) If the runout of flywheel exceeds the limit, replace. ++.
Limit: 0.13 mm (.0051 in.)
DRIVE PLATE (Engine with an automatic transaxle)
Replace deformed, damaged, or cracked drive plates.
SERVICE POINTS OF REASSEMBLY NWUGAB
14. INSTALLATION OF CRANKSHAFT BEARING (UPPER)

Install the upper crankshaft bearing to the cylinder block.
There is an oil groove in the upper crankshaft bearing.
There is no difference between upper and lower bearings
for the center (with flange).
12. INSTALLATION OF CRANKSHAFT BEARING (LOWER)
Install the lower crankshaft bearing (with no oil groove;
there is no difference for center) to each bearing cap and
apply engine oil to bearing surfaces.
ENGINE <2.0L DOHC Engine> - Crankshaft, Flywheel and Drive Plate g-135
11. INSTALLATION OF BEARING CAP
‘I. _
(1) Verify the correct identification mark and the direction
of the arrow for installation.
Front of
engine
(Timing
belt side)
BEN02
(2) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct. If
the end play exceeds the limit, replace crankshaft
bearings.
Limit: 0.25 mm (.0098 in.)

Using the special tool, press-fit the oil seal into the
crankshaft rear oil case. Use a new oil seal.
DEN063
9. INSTALLATION OF OIL SEPARATOR

Force the oil separator into the oil seal case so that the oil
hole in the separator is directed downward (arrow in
illustration).
6ENO48
-
9-136 ENGINE <2.0L DOHC Engine> - Cylinder Block
CYLINDER BLOCK
DISASSEMBLY AND REASSEMBLY maw-0 ,+Y
30-42 Nm
22-30 ft.lbs. 50-75 Nm
/ 40-54 ft.lbs.
4a Roll stopper
<Non-Turbo> bracket, front
/
’c /.
r.‘?’
<T7! o
-Cylinder block
50-76 Nm
36-51 ftlbs.
’ Engine support
bracket, left Roll stopper
bracket, rear
32-42 Nm 110-130 Nm
22-30 ftlbs. 60-64 ft.lbs.
6EN0374
INSPECTION
NOTE
1. Clean parts to remove dust, oil, carbon deposits, and scale
before starting the inspection and ‘repair procedure.
2. Check cylinder block for water leaks and damage b&fore
cleaning.
3. Remove deposits from oil holes and make sure that they
are not clogged.
4. Keep parts neatly arranged according to a matched pair.
CYLINDER BLOCK
(1) Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects are ~
evident, correct, or replace.
(2) Using a straightedge and feeler gauge, check the block top -
surface for warpage. Make sure that the surface is free
from gasket chips and other foreign matter.
Standard value: 0.05 mm (4020 in.) or less
Limit: 0.1 mm (AM40 in.)
ENGINE <2.0L DOHC Engine> - Cylinder Block 9437
(3) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm (008 in.)
The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head is 0.2 mm (008 in.) at maximum.
Cylinder block height (when new): 284 mm (11.18 in.)
(4) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
(5) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D.: 85.00-85.03 mm (3.3485-3.3476 in.)
Out-of-roundness and taper of cylinder bore:
0.01 mm (6064 in.) or less
CYLINDER REBORING NO9VEDCa
(1) Oversize pistons to be used should be determined on the

basis of the largest bore cylinder.
Piston size identification
Size Identification mark

0.25 mm (.Ol in.) O.S. 0.25
0.50 mm (.02 in.) O.S. 0.50
0.75 mm (.03 in.) OS. 0.75
1.00 mm LO4 in.) O.S. 1 .oo
Thrust
direction
NOTE
Size mark is stamped on piston top.
6EN054
-
(2) Measure outside diameter of piston to be used. Measure it
in thrust direction as shown.
(3) Based on measure piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) - 0.02 mm (.OOOS
in.) (honing margin)
(4) Bore all cylinders to calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, working from No.2
to No.4 to No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
<Non-Turbo>: 0.02-064 mm (AMOS-,001~ in.)
<Turbo>: 0.03-0.05 mm (.OOW-.O020 in.)
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
NOTES
,‘Z
11-l
INTAKE AND
EXHAUST
CONTENTS NllAA--
AIR CLEANER . . . . . . . ..*........................................ 8 Air Cleaner Element Inspection and

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST MANIFOLD <1.8L Engine> . . . . . . . . 26 Supercharging Pressure Control System
Inspection .,..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXHAUST MANIFOLD <2.0L DOHC Engine
Supercharging Pressure Relief Solenoid
(Non-Turbo)> . . . . . . ..*.*....................................... 27 7
Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD <2.0L DOHC Engine Turbocharger Supercharging Pressure
(Turbo)> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *........................... 28 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- EXHAUST PIPE AND MAIN MUFFLER SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..#................ 4

<1.8L Engine, 2.0L DOHC Engine
(Non-Turbo)> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SPECIFICATIONS ............................................. 2
EXHAUST PIPE AND MAIN MUFFLER
<2.0L DOHC Engine (Turbo)> . . . . . . . . . . . . . . . . . . . . . 31
INTAKE MANIFOLD <1.8L Engine> . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INTAKE MANIFOLD <2.0L DOHC Engine> 17 Abnormal Noise
11 Exhaust Gas Leakage
INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICE ADJUSTMENT PROCEDURES.. ..... 5
Air Bypass Valve Inspection ........................ 7
11-2 INTAKE AND EXHAUST - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NIICA-
.prt
Air cleaner
Element Unwoven cloth type
Exhaust system
Front exhaust pipe <Non-Turbo> Dual type
Front exhaust pipe <Turbo> Single type
Muffler Expansion resonance type
Coupling Flat coupling
Suspension system Rubber hangers and O-rings
Turbocharger
Type Exhaust gas turbine type
Identification No.
<M/T> TD05H-14B-6
4iT> TD04-13G-5
Supercharging pressure control Waste gate actuator and valve
Intercooler
Type Air cooled type
SERVICE SPECIFICATIONS NllCB- spr*
Items Standard L i m i t
Intake and exhaust manifolds

Distorsion of cylinder head contacting surface mm (in.) Less than 0.15 (.0059) 0.3 l.0121
Supercharging pressure solenoid valve terminal resistance 36-44
[at 20°C (68”F)l Q
Turbocharger
Supercharging pressure kPa (psi)
<MIT> 41-75 (6.0- 10.8)
<Al-r> 3 7 - 6 8 (5.4-9.9)
Waste gate valve opening pressure kPa (psi)
<MIT> Approx. 76.7 (11 .l)
<Al-r> Approx. 72.0 (10.4)
TORQUE SPECIFICATIONS NllCC-
Items Nm ftlbs.
Air cleaner
Air cleaner to body 8-10 6-7
Resonator 10-13 7-9
Air cleaner bracket 12-15 9-11
Intercooler
Intercooler to body 12-15 9-11
Air by-pass valve 15-22 11-16
Air pipe B 12-15 9-11
INTAKE AND EXHAUST - SDecifications II-3
Items Nm ft.lbs.
Intake manifold <1.8L Engine>
Accelerator cable to air intake plenum 4-6 3-4
Delivery pipe to intake manifold IO-13 7-9
Intake manifold stay 18-25 13-18
Engine hanger 15-20 II-14
Intake manifold to engine 15-20 11-14
Throttle body 15-22 II-16
Air intake plenum stay 15-20 11-14
Air intake plenum to intake manifold 15-20 11-14
Water outlet fitting 17-20 12-14
EGR valve IO-15 7-11
EGR temperature sensor <Vehicles for California> IO-12 7-9
Ground cable to air intake plenum 10-12 7-9
Control harness protector to air intake plenum 4-6 3-4
Cover IO-13 7-9
Intake manifold <2.0L DOHC Engine>
Accelerator cable to intake manifold 4-6 3-4
Throttle body stay 15-22 11-16
Delivery pipe to engine IO-13 7-9
Intake manifold stay 25-30 18-22
Intake manifold to engine
-- Mounting bolt (M8) 15-20 11-14
Mounting nut and bolt (MIO) 30-42 22-30
Ignition coil 20-27 14-20
Power transistor unit IO-12 7-9
Throttle body 15-22 11-16
EGR valve 15-22 II-16
EGR temperature sensor <Vehicles for California> IO-12 7-9
Control harness protector to intake manifold 4-6 3-4
Control harness clamp bolt IO-12 7-9
ixhaust manifold <1.8L Engine>
Front exhaust pipe to exhaust manifold 30-40 22-29
Front exhaust pipe to engine 30-40 22-29
Exhaust manifold cover (A) to exhaust manifold 27-33 20-24
Exhaust manifold cover (B) to exhaust manifold 20-28 14-20
Exhaust manifold cover (A) to exhaust manifold cover (B) 8-10 6-7
Exhaust manifold to engine 15-20 11-14
Oxygen sensor 40-50 29-36
Engine oil level gauge guide mounting bolt 12-15 9-l 1
ixhaust manifold <2.0L DOHC Engine (Non-Turbo)>
Front exhaust pipe to exhaust manifold 30-40 22-29
Heat protector (A), (B) 12-15 9-l 1
Exhaust manifold to engine 25-30 18-22
Engine hanger to engine 12-15 9-l 1
ixhaust manifold and turbocharger <2.0L DOHC Engine (Turbo)>
Front exhaust pipe to exhaust fitting 40-60 29-43
Heat protector (A), (B) 12-15 9-11
11-4 INTAKE AND EXHAUST - Specifications/Special Tool/Troubleshooting
Items Nm ft.lbs.
9-l 1 .-*
Engine oil level gauge guide mounting bolt 12-15
Engine hanger to engine 12-15 9-11
Exhaust manifold to engine 25-30 18-?2
Exhaust manifold to turbocharger 55-65 40-47
Oil pipe to engine 14-19 IO-l+
Water pipe (B) to water inlet pipe 40-50 29-36
Waste gate actuator IO-13 7-9
Water pipe (B) to turbocharger 35-50 25-36
Air outlet fitting 9-14 7-10
Oil pipe to turbocharger 28-34 20-25
Water pipe (A) to turbocharger 35-50 25-36
Water pipe (A) mounting bolt IO-12 7-9
Exhaust fitting 55-65 40-47
Oil return pipe 8-10 6-7
Exhaust pipe and main muffler
Front exhaust pipe to exhaust manifold <Non-Turbo> 30-40 22-29
Front exhaust pipe to exhaust fitting <Turbo> 40-60 29-43
Front exhaust pipe clamp 30-40 22-29
Rubber hanger IO-15 7-11
Front exhaust pipe to catalytic converter 40-60 29-43
Catalytic converter to center exhaust pipe 30-40 22-29
Hanger bracket to body 10-15 7-11
Hook to center exhaust pipe 10-15 7-11
Center exhaust pipe to main muffler 30-40 22-29
Moulding to main muffler 4-6 3-4
SPECIAL TOOL NllDA-
I Tool Number Name I Use I

Removal/Installation of oxygen sensor
Removal/Installation of oxygen sensor
TROUBLESHOOTING NllEAAB

Exhaust gas leakage Loose joints Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Broken separator in muffler Replace
Fs
Broken rubber hangers \
Interference of pipe or muffler with vehicle body Correct
Broken pipe or muffler Repair or replace
INTAKE AND EXHAUST - Service Adjustment Procedures 11-5
AIR CLEANER ELEMENT INSPECTION AND RE-
PLACEMENT NllQBAF
< 1.8L Engine, 2.0L DOHC Engine (Non-Turbo) >

(2) Remove the air intake hose.
(4) Push the air intake hose backward, and remove the air
cleaner cover.
Caution
cover, because the air-flow sensor is attached.
(6) Check the air cleaner element for dirt or clogging.
(7) Replace the air cleaner element if the dirt or clogging is
serious.
(8) Insert the element into the air cleaner body and install the
air cleaner cover.
(9) Install the air intake hose.
(10)Connect the air intake hose and the air-flow sensor
connector.
<2.0L DOHC Engine (Turbo)>
(I 1 Disconnect the air-flow sensor connector.
(2) Disconnect the boost hose.
(3) Disconnect the solenoid valve with hoses.
(4) Disconnect the air intake hose.
(5) Remove the air cleaner retaining bolts.
(6) Remove the air cleaner assembly.
Caution
Care must be taken when removing the air cleaner cover,
because the air-flow sensor is attached.
(9) Check the air cleaner element for dirt or clogging.
(10)Replace the air cleaner element if the dirt or clogging is
serious.
(11) Insert the element into the air cleaner body.
(12)Clamp the air cleaner cover.
(13)lnstall and tighten the air cleaner retaining bolts to the
specified torque.
(14)Connect the air intake hose and the solenoid valve.
(15)Connect the vaccum hose and the air-flow sensor
connector.
11-6 INTAKE AND EXHAUST - Service Adjustment Procedwes
TURBOCHARGER SUPERCHARGING PRESSURE
INSPECTION N1mAAB !PT
Caution
Perform running inspection with two passengers in the -’
vehicle and where full throttle acceleration can be safely
made.
The pressure gauge reading is taken by a front seat
passenger.
Wasie gate actuator (1) Disconnect the supercharging pressure control hose at the
05AOlSO
solenoid valve (fixed to the air cleaner) and plug the nipple.
Attach the pressure gauge to the hose.
(2) Drive the vehicle with full throttle and accelerate the engine
to a speed of more than 3,500 rpm at 2nd gear. Measure
the supercharging pressure when the pointer is stabilized.
Standard value:
M/T 41-75 kPa (6.0-10.8 psi)
A/T 37-68 kPa (5.4-9.9 psi)
Caution
If the supercharging pressure deviates from the standard
value, check the following items for possible causes.
When pressure is high:
Waste gate actuator malfunction
When pressure is low:
Waste gate actuator malfunction
Supercharging pressure leaks
Faulty turbocharger +-
SUPERCHARGING PRESSURE CONTRtd $YSTEM

INSPECTION NllGFAA
(1) After the self-diagnosis content of ECI-MULTI system is
completely read, turn off the ignition switch.
(2) Disconnect the vacuum hose (white-striped) from the waste
gate actuator, and connect the hand vacuum pump to the
vacuum hose.
(3) Disconnect the vacuum hose (black) from the intake port (A
in the figure) of the boost which controls the waste gate
actuator, and insert the blind plug into the nipple from which
the vacuum hose was disconnected.
(4) Keep the (- ) terminal of the battery disconnected for 10
seconds or longer, and then reconnect the terminal.
(5) Apply the negative pressure in the following state, and check
the air tightness.
I Engine state Hose (black) Normal state I
stop ;“““*I
NOTE
If negative pressure is not normal, it can be assumed that there is a
malfunction in the waste gate solenoid valve or vacuum hose.
INTAKE AND EXHAUST - Service Adjustment Procedures II-7
(6) With the vacuum hose (black) closed when idling, apply
negative pressure and inspect the condition of the negative
pressure.
Detonation sensor Normal state

Engine state connector
,
Negative pressure
Connection leaks.
Idling
Negative pressure
Disconnection
w 05A0155
is maintained.
NOTE
If negative pressure is not normal, it can be assumed that there is a
malfunction in the knock sensor circuit.
(7) Turn off the ignition switch, and connect the connector of
the detonation sensor.
(8) Disconnect the (-) terminal of the battery for 10 seconds or
more.
NOTE
This erases the diagnosis memory of the detonation sensor
trouble by disconnecting the detonation sensor connector.
SUPERCHARGING PRESSURE RELIEF SOLENOID

VALVE INSPECTION NllGGAA
(1) Operation check

Using a hand vaccum pump, apply a negative pressure to
h
the solenoid valve nipple on which the white vacuum hose
is connected, and check air-tightness when the voltage is
applied to the solenoid valve terminal and when it i‘s released
from the terminal.
Other nipple of Normal state

I Battery voile solenoid valve
61 NO060
Negative pressure
Opened leaks. I
When applied
Negative pressure
Closed by finger is maintained.
I When released Opened

Negative pressure
is maintained. I
(2) Continuity check of coil

Measure the solenoid valve terminal resistance.
61 NO061
Standard value: 36-44 fl [at 20°C (68OF)l
AIR BYPASS VALVE INSPECTION NllGHAA
(1) Remove the air bypass valve.

(2) Connect the hand vacuum pump to the nipple of the air
bypass valve.
(3) Apply a negative pressure of approx. 53.3 kPa (7.7 psi), and
check operation of the valve. Also check that air tightness
is maintained.
Negative pressure Valve operation

6 I NO056 About 53.3 kPa (7.7 psi) It starts opening.
II-8 INTAKE AND EXHAUST - Air Cleaner
AIR CLEANER
REMOVAL AND INSTALLATION NllFA- -%
< 1.8L Engine, 2.0L DOHC Engine (Non-Turbo) >
8-10 Nm 

6-7 ft.1bs.y ’
*l
LJ
<2.0L DOHC Engine (Non-Turbo)>
05A0179
IO-13 Nm
7-9 ft.lbs.
18
05A0140
Removal steps
1. Connection for air flow sensor
connector
2. Breather hose
3. Air intake hose
4. Air cleaner
9 5. Air cleaner cover
6. Air cleaner element
80 7. Air flow sensor assembly
8. Air flow sensor gasket
9. Noise reduction filter
4 10. Cover
11. Grommet
12. Air cleaner body
13. Insulator
14. Collar
15. Packing
16. Tuning pipe
17. Splash shield extension
18. Resonator
NOTE
*I: <1.8L engine>
05AO137 *2: <2.0L DOHC engine (Non-Turbo)>
INTAKE AND EXHAUST - Air Cleaner II-S
<2.0L DOHC Engine (Turbo)>
12-15 Nm
8-10 Nm 9- 11 ftlbs.
6-7, ft.lbs. /
05A0182
Removal steps
1. Air pipe B
2. By-pass air hose
3. Connection for air flow sensor
connector
4. Vacuum hose
5. Waste gate solenoid valve
6. Breather hose
8 7. Purge hose
8. Air cleaner
9. Air intake hose
10. Air cleaner bracket
11. Air cleaner cover
18 12. Air cleaner element
13. Air flow sensor assembly
14. Air flow sensor gasket
15. Noise reduction filter
16. Cover
17. Grommet
18. Air cleaner body
19. Insulator
20. Collar
05AO167
NOTE
INTAKE AND EXHAUST - Air Cleaner
INSPECTION NllFCAB
0 Check the air cleaner body, cover or packing for ~

deformation, corrosion or damage. %a
l Check the air duct for damage. d
0 Check the air cleaner element for clogging, contamination or
damage.
If element is slightly clogged, remove dust by blowing air
from inside of element.
AIR-FLOW SENSOR CHECK

For inspection of air-flow sensor, refer to GROUP 14-Air-Flow
Sensor Check.
< Non-Turbo > INTAKE AIR TEMPERATURE SENSOR N14QHABa
Air flow sensor (1) Disconnect the air flow sensor connectors.
side connector (2) Measure resistance between terminals @ and @
< Non-Turbo > .
(3) Measure resistance between terminals @ and @ <Turbo>. zJ
I Temperature”C (“F) I Resistance kn

0 (32) 6.0
6FUO622
20 (68) 2.7
80 (176) 0.4
c Turbo >
6FUO623
(4) Measure resistance while heating the sensor using a hair

drier.
Temperature’C (OFI Resistance kdl

Higher Smaller
(5) If the value deviates from the standard value or the resistance
remains unchanged, replace the air flow sensor assembly.
INTAKE AND EXHAUST - Intercooler 11-11
INTERCOOLER
A-- REMOVAL AND INSTALLATION NllTA-.
15-22 Nm
11-16 ft.lbs.
6
i
05AOl85
Removal steps
1. Air hose C
2. Air pipe B
3. Air by-pass hose
4. Vacuum hose
5. Vacuum hose
05A0140
l * 6. Air cleaner
7. Air intake hose
8. Air hose B
9. Splash shield extension
l + 10. Intercooler NOTE
11. Air hose A (1) Reverse the removal procedures to reinstall.
12. Air by-pass valve (2) l * : Refer to “Service Points of Removal”.
(3) *+ : Refer to “Service Points of Installation”
13. Gasket (4) q : Non-reusable parts
11-12 INTAKE AND EXHAUST - Intercooler
6. REMOVAL OF AIR CLEANER
Refer to P.l l-9.
INSPECTION NllTCAA
l Check the intercooler fins for bending, damage, or foreign

matter.
0 Check the intercooler hoses for cracking, damage, or wear.
SERVICE POINTS OF INSTALLATION NllTDAB
10. INSTALLATION OF INTERCObLER

Connect the air hoses and air pipes by aligning the paint
marks on the hoses with the projections and indentations on ?
the pipes.
Caution
Be careful not to allow any foreign matter to get into the
hoses, pipes, or the intercooler itself.
NOTE
05AO184 @ : Projection or indentation (pipe)
+ : Paint mark (hose)
INTAKE AND EXHAUST - Intake Manifold < 1.8L Engine> 11-13
INTAKE MANIFOLD < 1.8L Engine>
.- REMOVAL AND INSTALLATION NllMA-A
4-6 Nm
py---- 3-4 ft.lbs.
.- B 05A0132
IO-12 Nm
7-9 ft.lbs.
OlA0565
Removal steps
1. Air intake hose
2. Connection for accelerator cable Post-installation Operation
*Filling of Engine Coolant
4, l + 3. Connection for radiator upper hose (Refer to GROUP O-Maintenance
4. Connection for overflow tube Service.)
5. Connection for water by-pass hose aAdjustment of Accelerator Cable
6. Water hose (Refer to GROUP 14-Service Ad-
7. Connection for heater hose justment Procedures.)
8. Connection for brake booster vacuum hose *Inspection of Fuel Pressure
.. 9. Connection for fuel high pressure hose (Refer to GROUP 14-Service Ad-
10. O-ring justment Procedures.)
11. Connection for fuel return hose NfJTF
I.” IL
12. Connection for vacuum hoses (1) Reverse the removal procedures to reinstall.
13. Vacuum pipe (2) +* : Refer to “Service Points of Removal”.
14. PCV hose (3) l * : Refer to “Service Points of Installation”.
15. Connection for control harness (4) q : Non-reusable parts
II-14 INTAKE AND EXHAUST - Intake Manifold < 1.8L Engine>
lo-13 Nm
18 16 7-9 ft.lbs.
15-20 Nm
11-14 ft.lbs. I /
15-20 Nm
I
26
IO-15 Nm
7-11 ftm’bs.
-17-20 Nm
12-14 ft.lbs.
/ 15-20 Nm
15-20 Nm
11-14 ft.lbs.
05AO180
Removal steps
+* l a 16. Delivery pipe, fuel injector and pressure lb+ 29. Cover <Vehicles for Federal and Canada>
regulator 30. Gasket <Vehicles for Federal>
17. Insulator 31. EGR valve <Vehicles for California>
18. Insulator 32. EGR gasket <Vehicles for California>
19. Intake manifold stay 33. EGR temperature sensor <Vehicles for
20. Engine hanger California >
2 1. Thermostat housing 34. Water outlet fitting
22. Intake manifold 35. Gasket
23. Intake manifold gasket 36. Thermostat
24. Throttle body assembly
25. Gasket
26. Air intake plenum stay NOTE
27. Air intake plenum (1) Reverse the removal procedures to reinstall.
28. Air intake plenum gasket (2) a* : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service Points of Installation”
INTAKE AND EXHAUST - Intake Manifold < 1.8L Engine> 1145
SERVICE POINTS OF REMOVAL NllMBAI
3. DISCONNECTION OF RADIATOR UPPER HOSE

Make mating marks on the radiator hose and the hose
clamp, and then remove the radiator hose.
04A0088 1
9. DISCONNECTION OF FUEL HIGH PRESSURE HOSE

Relieve pressure in the fuel pipe line to prevent fuel
outflow.
(Refer to GROUP 14 - Service Adjustment Procedures.)
Caution
Cover fuel pipe line with rag after relieving pressure as
certain pressure may still remain.
r 16.REMOVAL OF DELIVERY PIPE, FUEL INJECTOR AND

PRESSURE REGULATOR
Remove delivery pipe with fuel injector and pressure
regulator.
Caution
Do not drop injector when removing delivery pipe.
INSPECTION NllMCAl
Check the following points; replace the part if a problem is

found.
AIR INTAKE PLENUM
(1) Check air intake plenum for defect or cracks. Replace if
defective or cracked.
(2) Check load (negative pressure) of drain port. Check
cooling water and jet air passages for clogging. Clean if
required.
(3) Check deflection of installation surface with straight edge
and feeler gauge.
Standard value: 0.15 mm (.006 in.) or less
Limit: 0.3 mm (.012 in.)
05AOOB4
II-16 INTAKE AND EXHAUST - Intake Manifold c 1.8L Engine>
INTAKE MANIFOLD
(1) Check for damage or cracking of any part. +4
(2) Check load (negative pressure) of drain port. Check ,
cooling water and jet air passages for clogging. Clean if
required.
(3) Check deflection of installation surface with straight edge
and feeler gauge.
Standard value: 0.15 mm (006 in.) or less
Limit: 0.3 mm (.012 in.)
05A0033
SERVICE POINTS OF INSTALLATION NllMDAXa
29. INSTALLATION OF COVER

Install the cover so that the side of the cover imprinted
“fj‘x? ‘Y bf4l~ (gasket side) is at the gasket side. -T
0580188
16. INSTALLATION OF DELIVERY PIPE, FUEL INJECTOR

AND PRESSURE REGULATOR
Caution
Be careful not to drop the injector when the delivery
pipe is installed.
3. CONNECTION OF RADIATOR UPPER HOSE

Mating marks
Align the mating marks on the radiator hose and the hose
clamp and install; then apply pressure where shown by
the arrows in the illustration so that the clamp is correctly
seated at the clamp’s previous trace indentations. A
Caution
Be absolutely sure that the hose clamp is correctly -
seated to its previous trace indentations.
INTAKE AND EXHAUST - Intake Manifold <2.0L DOHC Engine> I I-1.7
INTAKE MANIFOLD < 2.0L DOHC Engine>
^- REMOVAL AND INSTALLATION 4-6 Nm
NllMA-B
11-16 ft.lbs.
OSAO133
i3 4-6 Nm
3-4 ftlbs.
<Turbo>
lo-12 Nm
7-9 ft.lbs.
14 (Vehicles for
05AO139 05AOl89
Removal steps
I. Air intake hose <Non-Turbo>
2. Air hose C <Turbo> Post-installation Operation
3. Connection for control harness *Filling of Engine Coolant
4. Connection for accelerator cable (Refer to GROUP 0-Maintenance
Service.)
5. Ground plate installation screw @Adjustment of Accelerator Cable
6. Throttle body stay and ground plate (Refer to GROUP 14-Service Ad
7. Connection for water by-pass hose justment Procedures.)
8. Connection for water hose @Inspection of Fuel Pressure
9. Connection for brake booster vacuum (Refer to GROUP 14-Service Ad
hose justment Procedures.)
4* 10. Connection for fuel high pressure hose NOTF
,.-.-
11. O-ring (I) Reverse the removal procedures to reinstall.
12. Connection for fuel return hose (2) +e : Refer to “Service Points of Removal”.
13. Connection for PCV hose (3) q : Non-reusable parts
14. Connection for vacuum hoses *I: <Non-Turbo>
15. Connection for spark plug cable 1:; **: <Turbo>
11-18 INTAKE AND EXHAUST - Intake Manifold < 2.0L DOHC Engine>
18
h
IO-13 Nm
7-9 ft.lbs.
15-22 Nm
11-16 ft.lbs.
24
IO-12 Nm
10-27 Nm 7-9 ftlbs. 05A0197
14-20 ft.lbs.
15-22 Nm
11-16 ftlbs.
w
i2” v
lo-12 Nm
7-9 ftlbs. 25-30 Nm
18-22 ft.lbs.
‘27
\
28lll
<Turbo>
Removal steps 05A0196
+e l + 16. Delivery pipe, fuel injector and pressure

regulator 29. Connection for control harness
17. Insulator 30. Throttle body
18. Insulator 31. Gasket
19. Intake manifold stay
20. Intake manifold
21. Intake manifold gasket
22. Ignition coil
23. Power transistor unit
24. EGR valve
25. Gasket NOTE
26. EGR temperature sensor <Vehicles for (I) Reverse the removal procedures to reinstall.
California > (2) l * : Refer to “Service Points of Removal”.
27. Air fitting <Turbo> (3) l + : Refer to “Service Points of Installation”.
28. Gasket <Turbo> (4) 0 : Non-reusable parts
INTAKE AND EXHAUST - Intake Manifold <2.0L DOHC Engine> 11-19
SERVICE POINTS OF REMOVAL NllMBAJ
10. DISCONNECTION OF FUEL HIGH PRESSURE HOSE

Relieve pressure in the fuel pipe line to prevent fuel
outflow. (Refer to GROUP 14 - Service Adjustment
Procedures)
Caution
Cover fuel pipe line with rag after relieving pressure as
certain pressure may still remain.
16. REMOVAL OF DELIVERY PIPE, FUEL INJECTOR AND

PRESSURE REGULATOR
Remove delivery pipe with fuel injector and pressure
regulator on.
Caution
Do not drop injector when removing delivery pipe.
INSPECTION NllMCAJ

found.
INTAKE MANIFOLD
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum)
outlet port, and for obstruction of the water passage or
gas passage.
3. Using a straight edge and a thickness gage, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm (.006 in.) or less
Limit: 0.3 mm (012 in.)
05AOO28
SERVICE POINTS OF INSTALLATION NllMDAVa
16. INSTALLATION OF DELIVERY PIPE, FUEL INJECTOR

AND PRESSURE REGULATOR
Caution
Be careful not to drop the injector when the delivery
pipe is installed.
II-20 INTAKE AND EXHAUST - Turbocharger
TURBOCHARGER
REMOVAL AND INSTALLATION NHLA-
I I
Pre-removal Operation 1Po+installation Operation
*Draining Engine Coolant l Flllrng Engine Oil
(Refer to GROUP 0-Mainte (Refer to GROUP O-Main@
nance Service.) nance Service.)
*Draining Engine Oil l Filling Engine Coolant
(Refer to GROUP g-Engine (Refer to GROUP O-Mainte-
Adjustment.) nance Service.)
12-15 Nm
12-15 Nm
9- 11 ft.lbs.
12-15 Nm
9-l 1 ftlbs
moval steps
< Vehicles with air conditioner > h-50 Nm
29-36 ft.lbs.
) *4 2. Oxygen sensor
4. O-ring
5. Connection for air intake hose
6. Connection for vacuum hose
8. Connection for air hose A 05M1149
9. Air outlet fitting
10. Gasket 19. Connection for water hose
1 1. Heat protector A l * 20. Connection for water pipe f3
12. Heat protector B 21. Self-locking nut
13. Power steering oil pump 22. Gasket
14. Oil pump bracket 23. Exhaust manifold
15. Self-locking nut 24. Exhaust manifold gasket
16. Engine hanger 25. Ring
17. Eye bolt 26. Gasket
INTAKE AND EXHAUST - Turbocharger 11-21
26-34 Nm
35-50 Nm 20-25 ftlbs.
25-Qg ft-lbs* 36
\ /
55-65 Nm
4o-4: ft*lbs-
35-50 Nm
25-36 ftlbs.
27. Oil return pipe

05A0136
28. Gasket
l * l a 29. Turbocharger
30. Eye bolt
31. Gasket
32. Water pipe B
33. Eye bolt
34. Gasket
35. Water pipe A
36. Eye bolt NOTE
37. Gasket (1) Reverse the removal procedures to reinstall.
w l c 38. Oil pipe (2) l * : Refer to “Service Points of Removal”.
39. Exhaust fitting (3) l + : Refer to “Service Points of Installation”.
40. Gasket (4) q : Non-reusable parts

1 2. REMOVAL OF OXYGEN SENSOR
NllL9AD
Disconnect the connector of the oxygen sensor, and install

the special tool to the oxygen sensor.
Then, using an offset (box-end) wrench, remove the oxygen
sensor.
MD998748
INTeKE AND EXHAUST - Turbocharger
NOTE
the removal/installation of the turbocharger assembly.
29. REMOVAL OF TURBOCHARGER ASSEMBLY

Remove the turbocharger assembly with the exhaust fitting,
water pipe A, water pipe 6 and the oil pipe attached to it.
3B.REMOVAL OF OIL PIPE
Caution
After disconnecting the oil pipe, take care that foreign
material does not enter the oil passage hole of the
turbocharger assembly.
INSPECTION NllLCAC
TURBOCHARGER ASSEMBLY CHECK

l Visually check the turbine wheel and the compressor wheel
for cracking or other damage.
l Check whether the turbine wheel and the compressor wheel
can be easily turned by hand.
l Check for oil leakage from the turbocharger assembly.
l Check whether or not the waste gate valve remains open.
If any problem is found, replace the part after disassembly.
OIL PIPE AND OIL-RETURN PIPE CHECK

Check the oil pipe and oil-return pipe for clogging, bending, or
other damage.
If there is clogging, clean it.
SERVICE
-x_
POINTS OF INSTALLATION NllLDAC
3SlNSTALLATlON OF OIL PlPE

Supply clean engine oil through the oil pipe installation hole
of the turbocharger assembly.
29. INSTALLATION OF TURBOCHARGER ASSEMBLY

Clean the alignment surfaces shown in the illustration.
Caution
When cleaning, care must be taken so that a piece of the
gasket does not enter the oil passage hole.
I 05AOO26
INTAKE AND EXHAUST - Turbocharger II-23
20.lNSTALLATlON OF WATER PIPE (B)
05K557
2. INSTALLATION OF OXYGEN SENSOR

Use the special tool to install the oxygen sensor.
’ MD998748
05A0023
NllLE-.
lo-13 Nm
7-9 Mbs.
Disassembly steps
1. Snap pin
2. Waste gate actuator
3. Coupling
l 4. Turbine housing
l * l C 5. Snap ring
+e *a 6. Cartridge assembly
l * 7. O-ring
8. Compressor cover
NOTE
(2) 4~ : Refer to “Service Points of Disassembly”.
(3) ++ : Refer to “Service Points of Reassembly”. 6 1 NO084
II-24 INTAKE AND EXHAUST - Turbocharger
SERVICE POINTS OF DISASSEMBLY NllLFAB
5. REMOVAL OF SNAP RING

Place the compressor cover assembly on the floor with its
end surface down and remove the snap ring with pliers.
Caution
During removal, hold with a finger the snap ring which
can spring out.
6. REMOVAL OF CARTRIDGE ASSEMBLY

Remove the cartridge assembly by tapping the compressor
cover with a soft hammer.
Caution
Some resistance will be experienced in the removal due
to the O-ring on the cartridge assembly.
INSPECTION ;.rulim+A
TURBOCHARGER
1. Inspect the cast-iron turbine housing for damage, cracks, or
evidence of contact between the turbine blades and the
housing.
2. Manually open and close the waste gate valve to make sure
it operates freely.
3. Inspect the turbine and compressor wheels for wear,
damage, bent or broken blades.
4. Inspect the oil passage in the cartridge for signs of deposits
or blockage.
5. Clean the inlet section of the compressor cover with a rag.
Inspect it for signs of contact with the compressor turbine.
If worn, replace it.
WASTE GATE ACTUATOR

1. Leak-test the waste gate valve actuator with a hand vacuum
pump.
Replace the actuator if it does not hold vacuum.
2. Check the rod to see that it is not bent or binding.
SERVICE POINTS OF REASSEMBLY NllLHAB
Coat the inner surface of a new O-ring with a thin film of
engine oil, and set it in the groove of the cartridge assembly.
Caution
O-ring Be careful not to damage the O-ring while installing it as
oil leakage could result.
3EN239
INTAKE AND EXHAUST - Turbocharger ~1xz5
6. INSTALLATIQN OF CARTRIDGE ASSEMBLY
(I 1 Coat the outer circumference of the cartridge assembly
O-ring with a thin film of engine oil.
(29 Install the cartridge assembly on the compressor cover
by aligning the dowel pin.
Caution
When installing the cartridge assembly on the
compressor cover, be careful not to damage the
compressor wheel blades.
5. INSTALLATION OF SNAP RING

Place the cartridge assembly with the compressor cover
faced down and install the snap ring.
Caution
Install the snap ring with the tapered side of its outside
diameter up.
--=+I 61 NO070
4. INSTALLATION OF TURBINE HOUSING

Install the compressor cover and cartridge assembly on the
turbine housing with the dowel pin in alignment.
Caution
1. Be careful not to damage the blades of the turbine
wheel.
2. Be careful to install the turbine housing in the correct
direction.
TEST OF WASTE GATE ACTUATOR OPERATION

NllLlAA
Using a tester, apply a pressure to the actuator and make sure

that the rod moves.
Standard value:
M/T 76.7 kPa (11.1 psi)
A/T 72.0 kPa (10.4 psi)
Caution
Do not apply a pressure of more than 85.3 kPa (12.4 psi) to
6lN005E
the actuator. Otherwise, diaphragm may be damaged.
Never attempt to adjust the waste gate valve.
1 I-26 INTAKE AND EXHAUST - Exhaust Manifold c 1.8L Engine>
EXHAUST MANIFOLD < 1.8L Engine>

20-24 ft.lbs.
Removal steps’ 05A0135

2. O-ring
3. Self locking nut
4. Gasket
5. Oxygen sensor
7. Engine hanger NOTE
8. Exhaust manifold (1) Reverse the removal procedures to reinstall.
9. Exhaust manifold gasket (2) 4, : Refer to “Service Points of Removal”.
10. Exhaust manifold cover (B) (3) q : Non-reusable parts
SERVICE POINTS OF REMOVAL NHNBAG
5. REMOVAL OF OXYGEN SENSOR

sensor.
INSPECTION NllNCALO

found. -y=.
EXHAUST MANIFOLD
Check for damage or cracking of any part.
EXHAUST MANIFOLD GASKET
Check for flaking or damage of the gasket.
or blockage.
5. Clean the inlet section of the compressor cover with a rag.
Inspect it for signs of contact with the compressor turbine.
If worn, replace it.
WASTE GATE ACTUATOR

1. Leak-test the waste gate valve actuator with a hand vacuum
pump.
Replace the actuator if it does not hold vacuum.
2. Check the rod to see that it is not bent or binding.
SERVICE POINTS OF REASSEMBLY NllLHAB
Coat the inner surface of a new O-ring with a thin film of
engine oil, and set it in the groove of the cartridge assembly.
Caution +%
O-ring Be careful not to damage the O-ring while installing it as __
oil leakage could result.
3EN239
INTAKE AND EXHAUST - Exhaust Manifold <2.0L DOHC Engine (Non-Turbo) > 11-27
EXHAUST MANIFOLD < 2.0L DOHC Engine (Non-Turbo) >
REMOVAL AND INSTALLATION ,lcIii3\ NllNA6
steps
12-15 Nm
1. Condenser fan motor 9- 11 ft.lbs.
2. Self locking nut
3. Gasket
06AOl56
* * 5. Oxygen sensor
6. Self locking nut
8. Exhaust manifold (I) Reverse the removal procedures to reinstall.
9. Exhaust manifold gasket (2) +* : Refer to “Service Points of Removal”
1 0. Exhaust manifold cover (B) (3) 0 : Non-reusable parts
I-
SERVICE POINTS OF REMOVAL NllNSAH
5. REMOVAL OF OXYGEN SENSOR

sensor.
INSPECTION NllNCALl

found.
EXHAUST MANIFOLD
11-28 INTAKE AND EXHAUST - Exhaust Manifold ~2.0~ DOHC Enoine (Turbo)>
EXHAUST MANIFOLD <2.0L DOHC Engine (Turbo)>

REMOVAL AND INSTALLATION NllNA-C

*Draining Engine Coolant @Filling Engine Oil
(Refer to GROUP O-Mainte- (Refer to GROUP O-Mainte-
*Draining Engine Oil @Filling Engine Coolant
(Refer to GROUP O-Mainte- (Refer to GROUP O-Mainte-
130 25-30 Nm
d/18-22 ft.lbs.
\
30-40 Nm EJ \\=a-50 N
Rennova1 steps 2 2 - 2 9 ft.lty3. & (
4 .ri
,
2 9 - 3 8 ftk.
<Vehicles with air conditioner >

Oxygen sensor connector 05Ao154
;: Engine oil level gauge guide
4. O-ring 16. Gasket
Connection for air intake hose
s5:Connection for vacuum hose
7. Connection for vacuum hose 19IB
17. Connection for water hose
WI 18. Connection for water pipe B
19. Self-locking nut
Connection for air hose A 20. Gasket
:: Heat protector A 21. Exhaust manifold
10. Heat protector 6 2 2 . Exhaust manifold gasket
Ii. Power steering oil pump 23. Ring
12. Oil pump bracket 24. Gasket
15. Eve bolt (2) +, : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service Points of Installation”
INTAKE AND EXHAUST - Exhaust Manifold <Z.OL DOHC Enaine (Turbo)> II-28
SERVICE POINTS OF REMOVAL NllNBAl
11. DISCONNECTION OF POWER STEERING OIL PUMP :

NOTE
the removal/installation of the exhaust manifold.
OlAO552
lNSPECTlON NllNCALl

found.
EXHAUST MANIFOLD
SERVICE POINTS OF INSTALLATION NllNQAG
18. INSTALLATION OF WATER PIPE (BI

05K55; ,
lNTAKE AND EXHAUST _ Exhaust Pspe and Main Muffler
c 1.8L Engine, 2.0L DOHC Engine (Non-Turbo) >


REMOVAL AND INSTALLATION N1lRA-A
IO-15 Nm
7- 11 ft.lbs.
7- 11 ft.lbs.
IO-15 Nm 2 2 - 2 9 ft.lbs.
OSAO144
021’
30-k) Nm 40-60 Nm 30-&o Nm
22-29 ft.lbs. 29-43 ft.lbs. 22-29 ft.lbs.
Removal steps
1. Protector 16. Hanger bracket
2. Gasket 17. Center exhaust pipe
3. Hanger 18. Gasket
4. Main muffler 19. Catalytic converter
5. Moulding <2.0L DOHC engine (Non-Turbo)> 20. Gasket
6. Hanger bracket 21. Self locking nut
7. Rear heat protector panel 22. Hanger
8. Self locking nut 23. .Front exhaust pipe
IO. Hook 25. Front floor heat protector panel
11. Bracket
12. Stopper
13. Hanger bracket NOTE
14. Hanger (I 1 Reverse t h e removal procedures to reinstall.
15. Protector (2) q : Non-reusable parts
INSPECTION NHRCAHO
l Check the mufflers and pipes for corrosion or damage.

l Check the rubber hangers and rubber O-rings for
deterioration or damage.
l Check for gas leakage from mufflers and pipes.
INTAKE AND EXHAUST - %%%%z~~:~?&!!!% 11-31
i <2.0L DOHC Engine (Turbo)>
NllRAB
<FWD>
IO-15 NIT
IO-15 Nm
7- 11 ftlbs.
5
i /
-1
3’
IO-15 Nm
7-l 1 ftlbs.
05AO145
22-29 ft.lbs.
_h.. 40-60 Nm G-60 Nm
29-43 ftlbs. 29-43 ft.lbs.
<AWD>
IO-15 Nm
7-l 1 ft.lbs.
IO-15 Nm
7-l 1 ft.lbs.
IO-15 Nm
7-l 1 ft.lbs.
05AO168
40-60
29-43 Nm
ftlbs.
V
IO-15 Nm
7- 11 ft.lbs.
\
30-40 Nm
22-29 ftlbs.
Removal steps
1. Protector 16. Center exhaust pipe
2. Gasket 17. Gasket
3. Hanger 18. Catalytic converter
4. Main muffler 19. Gasket
5. Hanger bracket 20. Self locking nut
6. Rear heat protector panel 21. Hanger
7. Self locking nut 22. Front exhaust pipe
9. Hook 24. Front floor heat protector panel
10. Bracket
11. Stopper
12. Hanger bracket
13. Hanger NOTE
14. Protector (1) Reverse the removal procedures to reinstall
15. Hanger bracket t (21 q : Non-reusable parts
INSPECTION NllRCAHl
l Check the mufflers and pipes for corrosion or damage.

0 Check the rubber hangers and rubber O-rings for
deterioration or damage.
0 Check for gas leakage from mufflers and pipes.
14-I
FUEL SYSTEM
CONTENTS
AUTO-CRUISE CONTROL SYSTEM ........................................... 109 Self-Diagnosis ....................................................................... 58

AUTO-CRUISE CONTROL ....................................................... 140 Throttle Positron Sensor ..................................................... 63
SERVICE ADJUSTMENT PROCEDURES .............................. 135 Vehicle Speed Sensor .........................................................
Accelerator Cable, Throttle Cable and Auto-cruise MPI SYSTEM INSPECTION <2.0L DOHC Engine> ........... 23
Control Cable Inspection and Adjustment ........................ 136 Air Conditioner Power Relay .............................................. 82
Auto-cruise Control System Inspection ............................. 135 Arr Conditioner Swatch ........................................................ 79
lndrvrdual Parts Inspection .................................................. 137 Components Location ......................................................... 68
SPECIFICATIONS ..................................................................... 109 Control Relay ....................................................................... 81
General Specifications ................ ....................................... 109 EGR Control Solenoid Valve ............................................... 82
Service Specifications ......................................................... 109 EGR Temperature Sensor ................................................... 79
Torque Specrfications .......................................................... 109 Engine Coolant Temperature Sensor ................................. 76
TROUBLESHOOTING ............................................................... 110 Fuel Pressure Control Valve ............................................... 82
Auto-Cruise Control Circurt ................................................ 128 Idle Position Switch ............................................................ 77
Auto-cruise Control Components Location ........................ 126 Idle Speed Control Servo ................................................... 79
Auto-cruise Control Related Harnesses ............................. 125 Injectors ................................................................................ 79
Check Chart ........................................................................ 114 Intake Air Temperature Sensor .......................................... 76
Input Check ......................................................................... 123 Malfunction Indicator Light ................................................. 72
Self-diagnosis Check .......................................................... 121 Oxygen Sensor .................................................................... 78
Troubleshootrng Quick-reference Chart .............................. 110 Power Steering Oil Pressure Switch ................................. 79
ENGINE CONTROL ....................................................................... 105 Power Transistor ................................................................. 82
ENGINE CONTROL .................................................................. 107 Purge Control Solenoid Valve ............................................. 82
-- SERVICE ADJUSTMENT PROCEDURES .............................. 106 Self-Diaanosis ....................................................................... 73
Accelerator Cable Inspection and Adjustment .................. 106 ThrottletiPosition Sensor ..................................................... 77
Accelerator Switch Inspectron and Adjustment ................ 106 Vehicle Speed Sensor ......................................................... 79
SPECIFICATIONS ..................................................................... 105 SERVICE ADJUSTMENT PROCEDURES
Lubricants ............................................................................. 105 <1.8L Engine> ........................................................................ 41
Sealant ................................................................................. 105 Curb Idle Speed Inspection ................................................ 41
Service Specifications .......................................................... 105 EGR Valve Control Vacuum Check .................................... 47
Torque Specifications .......................................................... 105 Fuel Pressure Test .............................................................. 44
TROUBLESHOOTING ............................................................... 105 Fuel Pump Operation Check .............................................. 44
FUEL SYSTEM .............................................................................. 2 Idle Speed Control and Throttle Position
FUEL FILTER ............................................ . ............................... 104 Sensor Adjustment .............................................................. 41
FUEL LINE AND VAPOR LINE .............................................. 102 Purge Port Vacuum Check ................................................. 47
FUEL PUMP, FUEL GAUGE UNIT AND Release of Residual Pressure from
OVERFILL LIMITER (TWO-WAY VALVE) <AWD> ............. 101 High Pressure Fuel Hose ................................................... 44
FUEL PUMP, FUEL GAUGE UNIT AND Throttle Body (Throttle Valve Area) Cleaning .................... 43
OVERFILL LIMITER (TWO-WAY VALVE) <FWD> ............. 99 SERVICE ADJUSTMENT PROCEDURES
FUEL TANK <AWD> ............................................................. 97 <2.0L DOHC Engine> ............................................................ 48
FUEL TANK <FWD> .............................................................. 93 Basic Idle Speed Adjustment ............................................. 48
INJECTOR ................................................................................. 83 Curb Idle Speed Inspection ................................................ 48
MPI SYSTEM INSPECTION <1.8L Engine> ....................... 56 EGR Valve Control Vacuum Check .................................... 55
Air Conditioner Switch ........................................................ 64 Fuel Pressure Test .............................................................. 52
Air Conditioner Power Relay .............................................. 67 Fuel Pump Operation Check .............................................. 51
Components Location ...................................................... 56 Idle Position Switch Adjustment ........................................ 52
Control Relay ................. ................. ... ............................ 66 Purge Port Vacuum Check ................................................. 55
EGR Control Solenoid Valve ............................................... 67 Release of Residual Pressure from
EGR Temperature Sensor .................................................. 64 High Pressure Fuel Hose ................................................... 51
Engine Coolant Temperature Sensor ................................. 62 Throttle Body (Throttle Valve Area) Cleaning .................... 51
Idle Posrtion Switch ........................................................... 63 Throttle Position Sensor Adjustment ................................. 50
Idle Speed Control Servo ............................. .................... 65 SPECIAL TOOLS ...................................................................... 6
Inhibitor Switch .................................................................... 65 SPECIFICATIONS ..................................................................... 2
hjeCtOrS ................................................................................ 65 General Specifications ......................................................... 2
Intake Air Temperature Sensor .......................................... 6’2 Sealant and Adhesive ......................................................... 5
Malfunction lndtcator Light ............. ............................. 58 Service Specifications .......................................................... 4
Motor Position Sensor ...... .......................................... 63 Torque Specifications .......................................................... 5
Oxygen Sensor ............................... .................................. 64 THROlTLE BODY <1.8L Engine> ........................................ 85
Power Steering 011 Pressure Swatch ........................... 65 THROlTLE BODY <2.0L DOHC Engine> ............................ 89
Power Transistor ................................................................ 67 TROUBLESHOOTING ............................................................... 6
Purge Control Solenoid Valve ......................................... 67
14-2 FUEL SYSTEM - Specifications
FUEL SYSTEM
SPECIFICATIONS
NW%-
4.8L Engine>
Fuel
Tank capacity liter (gal.) 60 (15.9)
Return system Equipped
Filter High pressure type
Fuel pump
Type Electrical, in-tank type
Driven by Electric motor
Throttle body
Throttle bore mm (in.) 50 (1.97)
Throttle position sensor Variable resistor type
Idle speed control servo Electric motor
Idle position switch Contact type, within idle speed control servo
Motor position sensor Variable resistor type
Engine control unit

Identification model No.
For Federal and Canada E2T33674
For California E2T33673
Sensors
Air flow sensor Karman vortex type
Barometric pressure sensor Semiconductor diffusion type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Vehicle speed sensor Reed switch type
Inhibitor switch Contact switch type
No. 1 cylinder top dead center sensor Photo interrupter type
Crank angle sensor Photo interrupter type
EGR temperature sensor <California> Thermistor type
Actuators
Control relay type Contact switch type
Injector type and number Electromagnetic, 4
Injector identification mark N210H
Purge control solenoid valve ON/OFF type solenoid valve
EGR control solenoid valve <California> Duty cycle type solenoid valve
Fuel pressure regulator

Regulated pressure kPa (psi) 335 (47.6)
FUEL SYSTEM - Specifications 14-3
<2.0L DOHC Engine>
Fuel
Tank capacity liter (gal.) 60 (15.9)
Return system Equipped
Filter High pressure type
Fuel pump
Type Electrical, in-tank type
Driven by Electric motor
Throttle body
Throttle bore mm (in.) 60 (2.36)
Throttle position sensor Variable resistor type
Idle speed control servo Stepper motor type
The stepper motor type by- ass air control
system with the Fast Idle 6!rr Valve (FIAV)
Idle position switch Contact switch type
Engine control unit
Identification model No.
For Federal <Non-Turbo> E2T36572
<Turbo-FWD-M/T> E2T36574
<Turbo-FWD-A/T> E2T36576
<Turbo-AWD-M/T> E2T36578
<Turbo-AWD-AiT> E2T36582
For California <Non-Turbo> E2T3657 1
<Turbo-FWD-M/T> E2T36573
<Turbo-FWD-A0> E2T36575
<Turbo-AWD-M/T> E2T36577
<Turbo-AWD-AA> E2T36581
Sensors
Air flow sensor Karman vortex type
Barometric pressure sensor Semiconductor diffusion-type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Vehicle-speed sensor Reed switch type
Detonation sensor <Turbo> Piezoelectric device type
Top dead center sensor Photo interrupter type
Crank angle sensor Photo interrupter type
Power steering oil pressure switch Contact switch type
4ctuators
Control relay Contact switch type
Resistor identification model No. E8T05873
Injector type and number Electromagnetic, 4
Injector identification mark <Non-turbo> N240H
<Turbo-M/T> B450L
<Turbo-A/T> B390L
Purge control solenoid valve ON/OFF type solenoid valve
EGR control solenoid valve <California> Duty cycle type solenoid valve
Fuel pressure control solenoid valve <Turbo> ON/OFF type solenoid valve
Waste gate solenoid valve <Turbo> ON/OFF type solenoid valve
FUEL SYSTEM - Specifications
Regulated pressure kPa (psi) <Non-Turbo> 335 (47.6)
<Turbo-M/T> 255 (36.3)
<Turbo&T> 300 (42.7)
SERVICE SPECIFICATIONS
<1.8L Engine> N14CB-
Basic ignition timing 5”BTDC at curb idle

~Curb idle speed vm 700f 100
, Idle speed when air conditioner is on rpm 850 at neutral position
650 at D range <A/T>
Basic idle speed wm 700 f 50
Throttle position sensor adjusting voltage V 0.48-0.52 at curb idle
Throttle position sensor resistance kQ 3.5-6.5
Motor position sensor resistance k& 4-6
Idle speed control servo motor coil resistance 52 5-35 [at 20°C (68”F)l
Intake air temperature sensor resistance kQ 2.7 [at 20°C (68”F)I
Engine coolant temperature sensor resistance k8
20°C (68°F) 2.5
80°C (176°F) 0.3
Fuel pressure kPa (psi)
Vacuum hose disconnection 330-350 (47-50) at curb idle
Vacuum hose connection Approx. 270 (38) at curb idle
Iniectnr c o i l r e s i s t a n c e Q 13-16 [at 20°C (68”F)l
<2.0L DOHC Engine>
Items ( Specifications
Basic ignition timing 5”+ 2”BTDC at curb idle

Curb idle speed rpm 750+ 100
Idle speed when air conditioner is on rpm
<M/T> 850 at neutral position
al-r> 650 at D range
Basic idle speed rpm 750 f 50
Throttle position sensor adjustment voltage V 0.48-0.52 at curb idle
Throttle position sensor resistance kQ 3.5-6.5
Idle speed control servo (stepper motor) coil resistance Q 28-33 [at 20°C (68”F)l
Intake air temperature sensor resistance kQ 2.7 [at 20°C (68”F)I
Engine coolant temperature sensor resistance k0
20°C (68°F) 2.5
80°C (176°F) 0.3
Fuel pressure kPa (psi)
Vacuum hose disconnection <Non-Turbo> 330-350 (47-50) at curb idle
<Turbo-M/l> 250-270 (36-38) at curb idle
<Turbo-m> 290-320 (41-46) at curb idle
Vacuum hose connection <Non-Turbo> Approx. 270 (38) at curb idle
<Turbo-M/T> Approx. 190 (27) at curb idle
<Turbo-A/l> Approx. 230 (33) at curb idle
FUEL SYSTEM - SDecifications 14-5
-. Injector coil resistance 52 <Non-Turbo> 13-I 6 [at 20°C (68”F)j
<Turbo> 2-3 [at 20°C (68”F)I
TORQUE SPECIFICATIONS N14CC-A

Items I Nm 1 ft.lbs.
Center cover 2.5-3.5 2-3
Engine coolant temperature sensor 20-40 15-29
Throttle position sensor attaching screws 1.5-2.5 1.1-1.8
Idle speed control servo attaching screws <2.0L DOHC Engine> 2.5-4.5 1.8-3.3
Delivery pipe mounting bolts IO-13 7-9
High-pressure fuel hose to delivery pipe 4-6 3-4
Fuel pressure regulator to delivery pipe
<1.8L Engine> 7-l 1 5-8
<2.0L DOHC Engine> 8-10 6-7
Accelerator cable clamp IO-13 7-9
Throttle body mounting bolts and nuts 15-22 11-16
Throttle body stay mounting nut <Turbo> 15-22 11-16
4ccelerator cable adjusting bolts 4-6 3-4
Lateral rod attaching bolt 80-l 00 57-72
,,-
Self-locking nut 21-31 15-22
Fuel tank drain plug 15-20 11-14
Electrical fuel pump
Screws 2-3 1.4-2.2
Bolt (at lower side) 9-14 6.5-10
Gel gauge unit mounting screws 2-3 1.4-2.2
-ligh pressure hose to electrical fuel pump 30-40 22-29
iigh pressure hose to fuel main pipe 30-40 22-29
3attery tray to battery 2-3 1.5-2
3attery tray mounting bolt 9-14 7-14
Gel main pipe to fuel filter 30-40 22-29
Zye bolt 25-35 18-25
Gel filter mounting bolts 9-14 7-10
%el pipes clip attaching bolt 9-14 7-10
Japor pipe assembly mounting bolt 9-14 7-10
Ianister holder mounting bolt 9-14 7-10
SEALANT AND ADHESIVE NMCE-A

Engine coolant temperature sensor threaded portion MOPAR Part No.4318034 or equivalent
Fuel tank hole cover <AWD> MOPAR Rope Caulk Sealer 3/l 6 x 80” roll Part No.
14-6 FUEL SYSTEM - Special Tools/Troubleshooting
SPECIAL TOOLS NWA-B
Number Name Use
M D998742 Hose adapter l Measurement of fuel pressure (to be used

together with MD9987091
MD998709 Adapter hose l Measurement of fuel pressure (to be used

together with MD9987421
TROUBLESHOOTING N14EBBH
When checking and correcting engine troubles, it is (4) Ignition system

important to start with inspection of the basic l Spark plugs
systems. l High tension cable
In case you have such troubles as (1) engine start l Distributor <1.8L Engine>
failure, (2) rough idling or (3) poor acceleration, l Crank angle sensor <2.0L DOHC Engine>
therefore, you should first check the following basic 0 Ignition coil
systems: (5) Emission control system
(1) Power supply
l Crankcase ventilation system
0 Battery l Exhaust gas recirculation system
l Fusible link l Vacuum leak
l Fuse (6) Others
(2) Body ground 0 Ignition timing
(3) Fuel supply
l Idle speed
l Fuel line Troubles with the MPI system are often caused by
l Fuel filter poor contact of harness connector. It is, therefore,
l Fuel pump important to check harness connector contact.
FUEL SYSTEM - Troubleshooting 14-7
Engine will not start Trouble in the MPI system Check for output of self-diagnosis
or start too hard code.
(Cranks OK) Read the code with a voltmeter.
Malfunction of the fuel pump drive control system Check the fuel pump drive control
system and the fuel pump.
Malfunction of the ignition timing control system Check the ignition timing.
Malfunction of the power transistor Check the power transistor as a single

unit.
Power is not supplied to the engine control unit. Check the power supply circuit.
Malfunction of the control relay Replace.
Malfunction of the injector Check the injector drive circuit.

Check the injector as a single unit.
The fuel pressure is not proper. Check the fuel pressure.

I
Vacuum hose disconnected or damaged Repair or replace.
I
Malfunction of the engine control unit ) Replace.
Wire breakage or short circuit occurs in the Repair or replace.

harness, or the connector is improperly connected.
Rough idle or engine Trouble in the MPI system Check for output of self-diagnosis
stumbles code.
Read the code with a voltmeter.
Malfunction of the sensor Check the sensor-related circuit.

l Intake air temperature sensor Check the sensor as a single unit
l Engine coolant temperature sensor
l Barometric pressure sensor
l Ignition switch
l Idle position switch
l Throttle position sensor
l No. 1 cylinder TDC sensor, crank angle sensor

l TDC sensor, crank angle sensor
<2.0L DOHC Engine>
l Power steering oil pressure switch
l Air conditioner switch
l Inhibitor switch <A/T>
l Motor position sensor <1.8L Engine>
l Air flow sensor
0 Oxygen sensor
Malfunction of the engine control system Check the actuator-related circuit.
l Stepper motor <2.0L DOHC Engine> Check the actuator as a single unit.
l Injector
0 Power transistor
14-8 FUEL SYSTEM - Troubleshooting
iymptom Probable cause Remedy
<ough idle or engine Malfunction of the vehicle speed reed switch Check the vehicle speed reed switch.
#table
Vacuum hose disconnected or damaged. Repair or replace.
Malfunction of the engine control unit. Replace.
Wire breakage or short circuit occurs in the Repair or replace.

.ngine hesrtates or Trouble in the MPI system Check for output of self-diagnosis
oor acceleration code.

l Intake air temperature sensor Check the sensor as a single unit.
l Ignition switch

<2.0L DOHC Engine>
l Inhibitor switch <A/T>
l Motor position sensor 
l Air flow sensor
l Oxygen sensor
Malfunction of the engine control system Check the actuator-related circuit.

0 Injector
0 Power transistor
Malfunction of the air conditioner power relay Check the system, and the compo-
control system nents if the system is found defective.
Vacuum hose disconnected or damaged. Repair or replace.
Malfunction of the engine control unit. Replace.

Wrre breakage or short circuit occurs in the Repair or replace.
FUEL SYSTEM - Troubleshooting 14-S
Poor fuel mileage, Trouble In the MPI system Check for output of self-diagnosis
code.

l Intake air temperature sensor Check the sensor as a single unit.
l Ignition switch

<2.0L DOHC Engine>
l lnhrbrtor switch <A/T>
l Motor position sensor 
l Air flow sensor
0 Oxygen sensor
Malfunction of the engine control system Check the actuator-related circurt.
0 Injector
0 Power transistor

FUEL SYSTEM - Troubleshooting
CONTROL FUNCTIONS NWEEE- -
<1.8L Engine>
Function Air-fuel Ignition Idle Air con- Fuel Purge EGR

mixture timing speed ditioner control control
control control control power “d”,i2
relay control
Functional elements control
In- Power supply X X X X X X X
Put (Ignition switch coupled)
Power supply (battery backup) X X X X X X X
Air flow sensor X X X X
lgnitron switch ST terminal X X X

(start srgnal)
Power steenng oil pressure switch X
Jut- I n j e c t o r X
lut
Idle speed control servo X
Power transistor X
Arr conditioner power relay X

Control relay X
Purge control solenord valve X
EGR control solenoid valve X
<California>
NOTE
*: <A/T>
FUEL SYSTEM - Troubleshootina
<2.0L DOHC Engine>
Functron Arr-fuel lgnrtron Idle Air con- Fuel Fuel Purge EGR
mixture timrng speed drtroner pump pressure air contrc
control control control power drive control control
relay control
Functronal elements control
In Power supply X X X X X X X X
Put (ignrtron switch coupled)
Power supply (battery backup) Ix Ix Ix lx lx lx lx Ix
Top dead center sensor I x X I

1 Crank angle sensor IxlxIxIxIxI lxlx
Oxygen sensor I x I
Vehrcle speed sensor X X
Air conditioner switch X X” X
Power steering 011 pressure switch X
I
Detonation sensor <Turbo> X
lgnrtron switch X X X
lgnrtron switch ST terminal X X X
lnhibrtor switch <A/T> X X X”
)ut- Injector X
ut
Resistor <Turbo> X
Idle speed control servo X
Power transistor I 1x1 I I I I I

Arr condrtroner power relay X
Control relay X
Fuel pressure control valve <Turbo> X
Purge control solenord valve X
EGR control solenoid valve X
<California>
NOTE
*: <A/T>
FUEL SYSTEM - Troubleshootinn
MPI CIRCUIT
1.8L Engine <M/T>
VSIBLE ST1 IGNITION
3-- REI SWITCHtIGl)
c-59
12s
4 5 8
m
IGNITION
COIL
j;WKPUMP ISTOR
:ONNECTOR CRANK ANGL
AND TOP DE !iD
CENTER SENSOR
MPI
CONTROL
r
RELAY
\/ ---,L)‘
DISTRIBUTOR5 E
ASSEMBLY
I
'p c;
cu
h
n
nLk
6
08 C-64
b tci3 21
lsil
12
/- j4
39 E
‘---, I- - - - - - -.
1 V r
5
i 5
iz;.
-65
c -66
a
135-AC-U0514-NC
SUB Fl SIBLE
LINK(
3-BW
7 3 l-47 lo
l1 B
Q
'c?T I1
69
--I E ; A-22
I.I
10A
6 2 c-50
pil!Ezq: '12 C-58
14
COMBINATION
>
1 ;&&CATED
ON+OFF:
21OkPa@OPsI)
%iEi33lm
1
8 OWOFF:
CJ g#~~p384"8l~
a
0 21OOkPaC29BPsl)
C-69
iz
-1
c
C-6; _---.
13
cQ
C-65 6L C-64
MPI
CONTROL
RELAY
k%sEiow INMKR AIR

mmcR
AIR
nor
RRRew
A-36
\/ \/ \/ \/ \/
"3 "5 "4 "6 “1
3 s c3
m -s d
.02 C-64
MPI
CONTROL
UNIT
MOTOR IDLE EGR

W3P;;ON SWITCH BE"&@-j@"T f#nibi ;;i;;;ATURE
SENSOR B-02 (VEHICLES FOR
B-03 B-30 j-1 CALIFORNIA)
= y-Qgg&q/ Y B-06 m
[81
H
KX35-AC-U0614A-NC
MPI
CONTROL
RELAY
F EGR CONTROL
SOLENOID
i VALVE
d 'W CLES
1 CALIFORNIA)
I :‘, lo-16
x EDI
2
3
.&
8P, r
”
-L
1
,
-
.--
I 12
3 -6
al
I1
.--
2 A-47
3
u
I-
-
SELFDIAGNOSIS
1
,. B-26 B-04
12 POWER Em
@ i;EERING IDLE SPEED
OXYGEN CONTROL
= SENSOR F'tF=;;RE ACTUATOR
cz1 B-17 D
1.8L Engine <A/T>

IGNI IGNI JN
SWIl SWIT (IGl)
3-BW
7
30
c! 7
6
>1
I a
2 C-59, i COMBINATION 14
lEfBl
466
9@
IGNITION
COIL
7-
F
POWER
_ TRANSISTOR
CRANK ANGLE
k8
3
1-6 l-6
'31
104 C-64 4 22 C-66 ;4
MPl-
_-._
CONTROL
UNIT
35AC-U0515-NC
MA JSIBLE INHIBITOR IGNITION

LI:
- SWITCH SWITCHtIGl)
;;;bKPUMP
:ONNECTOR
MPI
CONTROL
RELAY
FF - 0
3
I
6 1
? 3 ac
Nt J c:
c1
r
C-64 6 C-65 09
---- 08
,__-__--____--____-_-------- -----
KXIS-AC-UOSlSA-NC
SUB SIBLE
LIN 1
AIR CONDITI ONER
CONTROL UN1 T
a3
LT
I
c:1
/tI ) c-12 EiEiEl

:A
I
I
2 C-58
@
10A d ONiOFF:
210kPa(30Dsl)
8%&33,, I 1
%3ff A
ONiOFF:
2700kPa (334~~1)
(2QQP.Y I )
7 C-67 !sI
s
d 4-SPEED
AUTOMATIC
TRANSAXLE
~~YfRoL
103 C-64 C-65.,65

MPI
CONTROL
RELAv
A-36
.02 C-64
MPI
CONTROL
UNIT
1 v V
--- ___ _-_ --- -----
C-6 4 ~ 106m 101 17 13 23 6
Lil cu
cu + h
,. .
ik f3 k3
5
,c-
f
! T ! ,
?
I I, I I I I
Ku 3 I Ai 5s E5 *
,,3 ,,5 ,,6 ,,2 ,,4
EGA
;;;;;;ATURE
(VEHICLES FOR
CALIFORNIA)
B-06 a
KX35-AC-U05158-NC
14-20 FUEL SYSTEM - Troubleshootinn
MPI
CONTROL
RELAY
g
r
NJECTOR
r
B-10
ml
1
C-65
E _------------------- ”-----------_------------- E
.----
TOR
IVE IC
-II
i
) .--
I ) 12
-----
58 33
pjiFBGgn<‘“, : 3 -6
lc
C-67 16
.-- 17
II II
f I 5 8
,-- J ;
jm t it
L-- -
21
3 I I
1 , 2
ry121314j5i61;fi;) D-05 2 7" [
I I
lolllll2lY3114115llell7~ ‘7
m 1
i
I 1
B-26 =
Ial
-5 IGNITION B-04
J/B i6%hENT Qm
coNNEcToR~#~R'~EED
ACTUAT@R
-_ 2.0L DOHC Engine (Non-Turbo) <M/T>
MAIN ;ER
LINK -
r t* ;&,
I
I
~#KPUMP Ia
CONNECTOR Irn
I CL
I
I
I
I
1@
I
E-69
., . 12
FUEL PUMP
I
I
I
I m
$I
I
I
I
I
I- 2
m
4.l
d
El
MPI
CONTROL
UNIT
X36-AC-UOSlB-NC
IGNI ON
SW11 (IGl)
:c
c
3-BW
30
1
7
-------C J/B
3
CiG c-45
1- 1 COIL
IGNITION
-J
ENGINE SPEED
ADJUSTMENT ION
CONNECTOR
B-15
c!
3a
I l- -
r
-+c
1
P
C-69
ti 7 3
r
r 3
9 a3
5 3
1
i
COMBINATION
METER(TACH0‘ 6
------_ 10
------ ------ 09 54
.------. 5
FUEL SYSTEM - Troubleshootinn
-.
AIR FLOW SENSOR

r INTAKK AlN AlN
A-36 TENPERAIURE
EENBOR
PLOU
BENBOR
_-
c
----. _-____-____--_q - - - - - -
19 14
T
5
c
I
2 1
ONY 2
3OFF
lfl IDLE
SWITCH =
4 EGR TEMPERATURE ENGINE THROTTLE
POSITION B-05 POWER
fi %i%kES FOR m STEERING OIL
CALIFORNIA) Pl?l?f;#RE
B-08 m B-30 I {mc
Ia
KX35-AC-UOBlBA-NC
cl
C-66
&.25-R-
T
FI I
PURGE
CONTROL
SOLENOID
VALVE
A-14
1
2
Ql
--------- AE-2 ------- &I

V
J.V v n V V
P P
5v
----__--~~__----~_ b
7-----__-------_-----.
18
d
--
;
z=
! EL
NO
CONNECTION
Z z >
A-
D-06 59
COMBINATION
METER
> P m
n
1
I- 1 I
1,
1
s
IGNITION OXYGEN
FRONT SIDE TIMING SENSOR OXYGEN
ADJUSTMENT CHECK SENSOR
CONNECTOR CONNECTOR
A-60 C-56 B-26
REVERSE SIDE jE& iD
31 a
a 4
6
-
SUB FU .E LINK @
r(
[P
I31 C-L
DUAL
EiB'F;RE
A-08
@P
1
A-39X ENGINE
34
IZI F%b%TURE
N SWITCH
.03
Y
XX%-AC-U05168-NC
2.0L DOHC Engine (Non-Turbo) <A/T>
'SIBLE IGNITION
I SWITCH(ST)
2
l-
1
6
:
I
4 E-47
pfiq
2-BW a
zi
c;
2 E-69
1
;;IJEKPUMP
ZONNECTOR M
FUEL PUMP
INH 1
SWI'
43
_” 2
m
IA
i
hI
c:I
56 4.L----- ,1- 04 C-64

-_------------~----~-___
. ...P
!F-I
:35-AC-UO517-NC
IGN [ON
SWI' f (IGl)
I
3-BW
I
------ I
l j
ENGINE SPEED
ADJUSTMENT
CONNECTOR
.\6 ..8 ,,l
r I\ /\ /\
7t
C-69
: :
l.i -7
4 2
c 3
r
2s
c
> lx m
>
3 3
C-67:
t
=
COMBINATION
METERCTACHO) El
------- 10
----------- 09 55 C-65 64
.------------------------------------;
,AIR FLOW SENSOR

9
A-36
B-04
I&
T-- 3
3 3*
it%$ -
k-3 116
----------lLLlU------------12J-----122 -6
IDI j8
--_ - 5----
9
h c
------------
i
! A-52
OH
21
OFF
IDLE
$ ;giZG;$MPERATURE ENGIIIE SWITCH =
COOLiiNT B-05 POWER
q (VEHICLES FOR
CALIFORNIA)
@bE$ATURE ~~ti%&i ml STEERING OIL
;;%fE;RE
B-02
B-30 1 fg&iJ B-17D
H
KX36-AC-U0617A-NC
al.
25-
)
PURGE
-
CONTROL
GOLENOID
VALVE
A-14 53
1 -
B
2
1
- -ati_-- - _- g-
1 2 11
_______-__--_---
A a I
105’
IL
2g&j
3 d 3
L -
C-60 1 t
Is_ II-- ,’
NO
CONNECTION
3
> 3 5 m
COMBINATION m
METER
!
10
~ 1
!
B-26
FUEL SYSTEM - Traubleshootinn
ZUB FUSII
c-50
ELC 4-SPEED
AUTOMATIC
TRANSAXLE
CONTROL UNIT
1
ENGINE
COOLANT
TEMPERATURE
SWITCH
IC
C-64 103
Q
I
KX3S-AC-UOSi’7B-NC
2.0L DOHC Engine (Turbo) <M/T>
$ER IGNITIOFi
MAIN SWITCH(1
LINK
i
I
,c
2-BW E
CL
,_________________ ___-__--_--_--~__-~-~~~ --- _____-- t,
c-59 6
?-BW AL
,-
G
Al
UE PUMP
Ii k-
&NhTOR
4 z
CL
MPI i
c&gOL I
C-63 I
I
I
\I \/
6 "7 "2 I
I
I
c
0 8 4
I
I
C g &I cl I
I
I
I
I
:
C-64
j6 108
---------------------------
C-64
;XSS-AC-UOSlO-NC
14-32 FUEL SYSTEM. - Troubleshooting
r0 1
c-54
J/B
1 1OA
t
I
J
IGNITION
COIL
B-14
-t I I I,JtpTiJ~PARK
ET ANATION
9 9 9
c-05
EmF i ,,8
/\
,,l
ADJUSTMENT W
CONNECTOR 41 " NAfi~ ISTOR
' B-15
Y
7 2
cl
3
METER(TACH0)
A.
-,
MPI
CONTROL
RELAY
_ 1.25-R
1
ck:I Y
Ft; Lo
cu
c c;2
A-36 SPEED I
CONTROL
ACTUATOR d4
/\2
6 1 3
-I J x
i
7-r
4 2 I--- 1 A-5 1
m A-32
m mp ( 3 0
E-i
al
-6
22 i7 i8 i9
--_ --. --
-
5v
FWD !AWD
IDLE
1
TIFF
SWITCH
[$G!6$$MPERATURE E#iiT THROTTLE B-05
(VEHICLES FOR p%4F&mJRE !ggpN q
CALIFORNIA) B-30 1 B-02
B-08 m l!!d j@&g
KX35-AC-UOBlBA-NC
14-34 FUEL SYSTEM - Troubleshootitlg
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
02 C-6L
-------
C-67
5
IGNITION
~!%%MENT
CONNECTOR >
1
A-60 I
@g LL
COMBINATION
METER
CHECK CONNECTOR
-
c-30
FRONT 6IDE POWER
/$imwq
- m?RING
REVERSE SIDE ib'FB#I?E

pi!i%dq B-17 D
FUEL SYSTEM - Troubleshooting M-35
SUB FUS:
7
'AIR
CONDlTiONER
CONTROL
% UNIT
C-40
1
12
a J
l c-47
B 1
J/B
@ 2351tPa w3PSl)
1OP *
L 7
-1
c-5c N
i
t:
OFi
C
k
d -_-----
3
25
it2t
C-64 03 165 C-65

MPI
CONTROL
UNIT
itXtK+AC-UOSiBB-NC
14-36 FUEL SYSTEM - Trotibleshooting
2.0L DOHC Engine (Turbo) <A/T>
IGNI IGNI: ON
SW17 SWIT( (IGl)
3-BW
J/B
0
10A
-1
~ C-52 4
3
c
c
¶
m 3466
2
WITHOUT
;TEE-
+
z
;I,,2
I\
II
_---_----
,~>r'JFF
:)lAN V
"3 “1
EsBME
ifi
A
8 ADJUSTMENT
CONNECTOR r N!#iE ISTOR
B-15
L.2 J
2 3
3 m
rw-
4
COMBINAT ION '1
I
METER
(TACHO) 0
\I 104 C-64
:__-_A__ ---- -----. 55 C-65
INHIBITOR "9
SW1 TCH
B-25 2
Ad
MPI
CONTROL
UNIT
(X35-AC-U051Q-NC
(SIBLE
MAIN
LINK
INI
SW; &ITOR IGNI ION
SWIT ;1(IGl
\
2-BG
5
bEEI
122
088
c-59
!%%KPUMP FWD AWD

CONNECTOR r
FUEL PUMP
AND GAUGE
ASSEMBILY
E-33
pmq
\- @
1 )1
E-69
12
FUEL
1
PUMP 3
3
-
.08 C-64
KX35-AC-UOblBA-NC
I SUB FUSII 3L E LINK @

52
IA
tc
i A-22
C-58
P
ELC 4-SPEED
AUTOMATIC
TRANSAXLE
CONTROL UNIT
COMBINATION 5 A-21
METER
c-05 ‘s
1
1 t!L 1
pgm&1c ENGINE
RELAY Fb&&iiTURE
3 OF?
C I SWITCH
\' A-19X
? B-31CQ12
E
a
-6 10
E
--- ______ -_-----_-.
5 3
: s
3&i C-64 103 A65 C-65
-/
MPI
CONTROL
RELAY
12IAK6 AI2 AIR PLOI

A-36
5v
C-64
4:
if FWD !AWD
“:cl pJ % F3
”
12
E3J
-6
-__ SWITCH
ABS
CONTROL
~~[GiT~MPERATURE ;;f$;$T THROTTLE B-05 UNIT
POSITION
n (VEHICLES FOR ~i#$j~TuRE SENSOR !a
c-17 CALIFORNIA) B-30 1 B-02
B-08 @JJ Id (m\
pj%imzq
KX35-AC-UOSlBB-NC
&.25_-R
Q I
WI I
(VEHICLES FOR
CALIFORNIA)
_ _ _- -_ - -_
4-SPEED
AUTOMATIC
~W&WfLE
UNIT
C-60
V
__--_--__-_--- - - - - - -
II
31 I
9
.I .I
1:
F
A
I
I
4Gizi
IGNITION
TIMING
ADJUSTMENT
-1
F CONNECTOR >
D-06 A-60 1
a s=
ml cr,
$ fW&NATION
\/
2"
:,cal,,4
ml2
"
11
"
1
w
1 1
4-l
c-45
-1 l
SELFDIAGNOSIS
CHECK CONNECTOR 4
c-30 ""Y#TION &$fjf!j
m,234
6678
C-54 5
'011
i
c-h
-
FRONT SIDE
p!lGJRq
REVERSE SIDE
07 B-26 mt
q p!Raq
FUEL SYSTEM - Service Adjustment Procedures <1.8L Engine> l-4-41

CURB IDLE SPEED INSPECTION NlIFiiAE
Caution
The improper setting (throttle valve opening) will increase
exhaust gas temperature at deceleration, reducing catalyst
life greatly and deteriorating exhaust gas cleaning per-
formance. It also has effect on fuel consumption and
engine braking.
PI-e-conditions for inspection
0 Engine coolant temperature: 85-95°C (185-205°F)
0 Lights, electric cooling fan and accessories: OFF
l Transaxle: Neutral (P for vehicles with an automatic
ilter
transaxle)
l Steering wheel: Neutral position (vehicles with a power
steering)
l Check ignition timing and adjust if necessary. Refer to
GROUP 8.
Paper clip
NOTE
16A0898 With vehicles for Canada, the headlights and taillights, etc.
remain on even when the lighting switch is turned OFF, but this
causes no problems during inspection.
(1) Insert the paper clip to the connector.
(2) Connect the tachometer to the inserted clip.
(3) Run the engine for more than 5 seconds at an engine speed
of 2,000 to 3,000 rpm.
(4) Run the engine at idle for 2 minutes.
(5) Read the idling rpm. If it is not within the specified speed,
check the idle speed control system.
Curb idle speed: 700 f 100 rpm
NOTE
Adjustment of the idling speed is usually unnecessary,
because this system controls the idling speed.
IDLE SPEED CONTROL AND THROTlLE POSI-

TION SENSOR ADJUSTMENT N14FIAT
Adjustment conditions
l Engine coolant temperature: 85-95X (185-205°F)
l Lights, electric cooling fan and accessories: Set to OFF
l Transaxle: Neutral (P for vehicles with an automatic
transaxle)
l Steering wheel: Neutral position (vehicles with a power
steering)
(1) Slacken the accelerator cable enough.

(2) Connect a tachometer.
14-42 FUEL SYSTEM - Service Adjustment Procedures C1.8L Engine>
(3) Connect a digital voltmeter between terminal 19 (throttle

position sensor output voltage) of the engine control unit k
and terminal 24 (ground).
(4) Set the ignition switch at ON (without starting the engine)
hold it in that position for more than 15 seconds or more.
(5) Set the ignition switch at OFF.
6FU13%
Idle speed control (6) Disconnect the connectors of the idle speed control servo
and lock the idle speed control plunger at the initial position.
(7) Back out the fixed SAS enough.
(8) Start the engine and let it run at idle.

(9) Check to ensure that the engine is running at the standard
basic idle speed.
Basic idle speed: 700&50 rpm Lr
Caution
1. On a new vehicle [driven less than 500 km (380
miles)], the engine speed may ‘be 20 to 100 rpm
lower, but no adjustment is necessary.
2. If the engine stalls or the engine speed is low after
the vehicle has been driven a distance of 500 km
(300 miles) or more, a deposit on the throttle valve
area is suspected. Clean the throttle valve area.
(10)lf the engine speed does not conform to the standard
value, adjust it with the idle speed control adjusting screw.
Caution
When adjusting the idle speed control, use a hexagon
wrench whenever possible.
(11)Turn in the fixed SAS .until the engine speed rises. Then
back out the fixed SAS until the “touch point” where the
engine speed does not fall any longer is found. Back out the
adjusting screw fixed SAS an additional half a turn from the touch point.
(12)Stop the engine.
(13)Set the ignition switch at ON (do not start the engine) and
check that the output voltage from the throttle position
sensor is as specified.
Standard value: 0.48-0.52 V
A
FUEL SYSTEM - Service Adjustment Procedures <1.8L Engine> 14-43
(14)lf it is out of specification, adjust by loosing the throttle
position sensor mounting screws and rotating the throttle
position sensor. After adjustment, tighten the screws
firmly.
NOTE
Clockwise rotation of the throttle position sensor increases
the output voltage.
Throttle position
sensor / /I
t-
(15)Set the ignition switch at OFF.

(16)Adjust the free play of the accelerator cable.
(17)Reconnect the connectors of the idle speed control servo.
(18)Remove the voltmeter.
(19)Start the engine and check that the engine is running at the
curb idle speed.
Curb idle speed: 700f 100 rpm
(20)Set the ignition switch at OFF, disconnect the negative
battery cable and reconnect it more than 10 seconds later
(By doing so, the memory storing the diagnosis data during
the idle speed control adjustment is cleared.)
(21)Restart the engine, let it run at idle for about 5 minutes, and
check that the engine is running in good idle quality.
THROTTLE BODY (THROTTLE VALVE AREA)

CLEANING NllRCK
(1) Warm up the engine, then stop it.

(2) Remove the air intake hose from the throttle body.
(3) Spray cleaning solvent into the valve through the throttle
body intake port and leave it for about 5 minutes.
(4) Start the engine, race it several times and idle it for about 1
minute. If the idling speed becomes unstable slightly open
the throttle valve to keep the engine running.
(5) If the throttle valve deposits are not removed, repeat steps
(3) and (4).
(6) Attach the air intake hose.
(7) Disconnect the battery terminal for 10 seconds or more,
and then reconnect it.
(8) Adjust the idle speed control and throttle position sensor.
FUEL SYSTEM - Service Adjustment Procedures 4.8L Engine>
RELEASE OF RESIDUAL PRESSURE FROM HIGH

PRESSURE FUEL HOSE N14FGAE
Make the following operations to release the pressure remain-
ing in fuel pipe line so that fuel will not flow out.
(1) Disconnect the fuel pump harness connector at the fuel
tank rear side.
(2) Start the engine and after it stops by itself, turn the ignition
switch to OFF.
(3) Disconnect the battery (-) terminal.
(4) Connect the fuel pump harness connector.
FUEL PUMP OPERATION CHECK Nl4FDAG

(2) Check that when the batten/ voltage is directly applied to
the fuel pump check terminal, the operating sound of the
pump can be heard.
NOTE
Since the fuel pump is installed in the fuel tank, its
operating sound cannot be readily heard. Remove the fuel
tank cap and listen to the operating sound through the filler
port.
(3) Hold the high pressure fuel hose between your fingers and
check that the fuel pressure can be felt.
FUEL PRESSURE TEST Nl4FNAN
(1) Reduce the fuel pressure in the fuel line.

(2) Disconnect the high pressure fuel hose from the delivery
pipe.
Caution
Cover the hose connection with shop towel to prevent
splash of fuel that could be caused by residual pressure
(3) Connect a fuel pressure gauge to the special tool (hose

adapter).
Use a suitable O-ring or gasket between the fuel pressure
gauge and the special tool so as to seal in order to prevent
fuel leakage at this time.
-
MD998709
MD998742
IFUO157
FUEL SYSTEM - Service Adjustment Procedures 4.8L Engine> 14-45
(4) Install the special tool, which was set in place in step (3),
between the delivery pipe and the high pressure fuel hose.
(5) Connect the 0 terminal of the batten/.
(6) Apply battery voltage to the fuel pump check terminal and
activate the fuel pump; then, with fuel pressure thus
applied, check to be sure that there is no fuel leakage from
the pressure gauge or the special tool connection part.
(7) Start the engine and run at curb idle speed.

(8) Disconnect the vacuum hose form the pressure regulator
and clog the vacuum hose end. Measure the fuel pressure.
Standard value: 330-350 kPa (47-50 psi) at curb idle
(9) Measure the fuel pressure when the vacuum hose is

connected to the pressure regulator:
Standard value: Approx. 270 kPa (38 psi) at curb idle
(10)Race the engine repeatedly in two or three series. Then
check that the fuel pressure does not fall when the engine
is running at idle.
(11)Check to be sure that there is fuel pressure in the return
hose also (by gently pressing the fuel return hose with a
finger while repeatedly racing the engine).
NOTE
There will be no fuel pressure in the return hose when the
volume of fuel flow is not sufficient.
(12)lf the results of the measurements made in steps (8) and
(9) above are not within the standard value, use the table
below to determine the probable cause, and then make the
necessan/ repair.
14-46 FUEL SYSTEM - Service Adjustment Procedures <1.8L Engine>
Condition Probable cause Remedy
Fuel pressure too low a. Clogged fuel filter a. Replace fuel filter.
b. Fuel leaking toward return port due to b. Replace fuel pressure regulator.
improper seating of valve in fuel pressure
regulator
c. Low delivery pressure of fuel pump c. Replace fuel pump.
Fuel pressure too high a. Stuck valve in fuel pressure a. Replace fuel pressure regulator.
regulator
b. Clogged or bent fuel return hose or pipe b. Repair or replace hose or pipe. ‘.
Fuel pressure with a. Clogged or broken vacuum hose or nipple a. Repair or replace the vacuum hose or
vacuum hose connected nipple.
not different from fuel b. Stuck valve in fuel pressure regulator or b. Replace fuel pressure regulator.
pressure with vacuum defective valve seating
hose not connected
(13)Stop the engine and check for change in fuel pressure

gauge indication, which should not drop.
If the gauge indication drops, observe the rate of drop and
determine and remove the causes according to the
following table.
Fuel pressure drops Leakage from injector Replace injector.

slowly after engine is
stopped.
rq
Fuel pressure drops im- Check valve in fuel pump does not close Replace fuel pump.
mediately after engine is
stooped.
(14)Reduce the fuel pressure in the fuel line.

(16)Disconnect the high pressure fuel hose and remove the
fuel pressure gauge from the delivery pipe.
Caution
Cover the hose connection with shop tdwel to prevent
(16)Mount a new O-ring in the groove at the end of the high

pressure fuel hose.
(17)Connect the high pressure fuel hose to the delivery pipe,
and tighten the screws to the specified torque.
(18)Check for fuel leaks.
@ Apply battery voltage to the fuel pump check terminal -
to operate the fuel pump.
@ With fuel pressure acting, check the fuel line for leaks.
EGR VALVE CONTROL VACUUM CHECK

<California>
Check Condition
Engine coolant temperature: 85-‘95”C (185-205°F)
(1) Disconnect the vacuum hose from the throttle body EGR
vacuum nipple and connect a hand vacuum pump to the
nipple.
(2) Start the engine and check to see that, after raising the
engine speed by racing the engine, vacuum raises pro-
portionately with the rise in engine speed.
NOTE
If there is a problem with the change in vacuum, it is
A possible that the throttle body port may be clogged and
require cleaning.
E
3
x
>
/ )
Engine speed (rpm) 1 FU446
PURGE PORT VACUUM CHECK N14FvBc

Check Condition
(1) Disconnect the vacuum hose from the throttle body purge
hose nipple and connect a hand vacuum pump to the
nipple.
engine speed by racing the engine, vacuum remains fairly
constant.
NOTE
If there is no vacuum created, it is possible that the throttle
body port may be clogged and require cleaning.
>
Engine speed (rpm) 3FU262
<2.0L DOHC Engine>
CURB IDLE SPEED INSPECTION N14FHAD
Caution
The improper setting (throttle valve opening) will increase
exhaust gas temperature at deceleration, reducing catalys-
tic converter life greatly and deteriorating exhaust gas
cleaning performance. It also has effect on fuel ‘consump-
tion and engine braking.
Pre-conditions for inspection
l Lights, electric cooling fan and accessories: OFF
l Transaxle: Neutral (P for vehicles with automatic transaxle)
l Steering wheel: Neutral position (vehicles with a power-
steering)
l Check ignition timing and adjust if necessary. Refer to
GROUP 8.
NOTE
With vehicles for Canada, the headlights and taillights, etc.
remain on even when the lighting switch is turned OFF, but this
causes no problems during inspection.
(1) Connect the tachometer to the engine speed detection
terminal.
(2) Run the engine for more than 5 seconds at an engine speed
of 2,000 to 3,000 rpm.
(3) Run the engine at idle for 2 minutes.
(4) Read the idling rpm. If it is not within the specified speed,
check the idle speed control system.
Curb idle speed: 750f 100 rpm
NOTE
1. Adjustment of the idling speed is usually unnecessary,
because this system controls the idling speed.
2. For rpm, one-half of the actual engine rpm is indicated,
so the actual engine rpm is two times the indicated
value shown by the tachometer.
BASIC IDLE SPEED ADJUSTMENT N14FHBI
Pre-conditions for inspection

l Lights, electric cooling fan, and accessories: OFF
l Transaxle: Neutral (P for vehicles with automatic transaxle)
l Steerig wheel: Neutral position (vehicles with a power-
steering)
(1) Connect a tachometer.

(2) Disconnect the female connector (for waterproof protec-
tion of the connector) from the connector for ignition timing
adjustment.
(3) Connect the ignition timing adjusting terminal to the ground
using a jumper wire with alligator clips.
(4) Connect terminal No. 10 of the self-diagnosis connector to

the ground with a jumper wire with alligator clips.
(5) Start the engine and run at idle.
Terminal
(6) Check to be sure that the engine idling speed is the basic
No.10 idle speed.
Basic idle speed: 750 250 rpm
If there is a deviation of the engine speed from the basic
idle speed, first determine whether or not the conditions
described below exist, and then use the speed adjustment
screw to adjust to the basic idle speed.
(a) The engine speed may be 20-100 rpm low for a
new vehicle [driven about 500 km (300 miles) or
less], but adjustment is not necessary.
(b) If engine stalling occurs or the engine speed is low
even though the vehicle has been driven about 500
km (300 miles) or more, it is probable that these are
deposits adhered to the throttle valve, so it should
be cleaned.
(Refer to P.14-51.)
(c) If the engine speed is higher than the standard
screw value even though the speed adjusting screw is
fully close, check for any indication that the idle
position switch (fixed speed adjusting screw) posi-
tion has changed; if there is such an indication,
adjust the idle position switch (fixed speed adjust-
ing screw).
If there is no evidence of a change of position, it is
probable that there is leakage resulting from de-
terioration of the fast-idle air valve (FIAV), so
replace the throttle body.
(7) Turn OFF the ignition switch and stop the engine.
(8) Disconnect the grounding jumper wire from the diagnosis
connector.
(9) Disconnect the grounding jumper wire from the ignition
timing connector and mount a waterproof connector.
(1O)Disconnect the tachometer.
(11)Star-t the engine once again and let it idle for about 5
minutes; check to be sure that the idling condition is
normal.
THROllLE POSITION SENSOR ADJUSTME!-T’“.

(1) Slacken the accelerator cable enough.
(2) Connect a digital voltmeter between terminal 19 (throttle

position sensor output voltage) of the engine control unit
and terminal 24 (ground).
(3) Set the ignition switch at ON (do not start the engine) and
check that the output voltage from the throttle position
sensor is as specified.
Standard value: 0.48-0.52 V
6FU13%
(4) If it is out of specification adjust by loosening the throttle

position sensor mounting screws and rotating the throttle
position sensor. After adjustment, tighten the screws
firmly.
NOTE
1. Clockwise rotation of the throttle position sensor
increases the output voltage.
2. For information concerning the removal and installation
of the throttle body, refer to P.14-89.
(6) Adjust the free play of the accelerator cable.
(7) Remove the voltmeter.
(8) Disconnect the negative battery cable, and reconnect it
more than 10 seconds later. (By doing so, the memory
storing the diagnosis data during the idle speed control
adjustment is cleared.)
THROTTLE BODY (THROTTLE VALVE AREA)
CLEANING Nl4FtU
(1) Warm up the engine, then stop it.

(2) Remove the air intake hose from the throttle body.
(3) Plug the bypass passage inlet of the throttle body.
Caution
Do not allow cleaning solvent to enter the bypass
passage.
(4) Spray cleaning solvent into the valve through the throttle
body intake port and leave it for about 5 minutes.
(5) Start the engine, race it several times and idle it for about 1
minute. If the idling speed becomes unstable (or if the
engine stalls), slightly open the throttle valve to keep the
engine running.
(6) If the throttle valve deposits are not removed, repeat steps
(4) and (5).
(7) Unplug the bypass passage inlet.
(8) Attach the air intake hose.
(9) Disconnect the battery terminal for 10 seconds or more,
and then reconnect it.
(lO)Adjust the basic idle speed. (Refer to P.14-48.)
RELEASE OF RESIDUAL PRESSURE FROM HIGH

PRESSURE FUEL HOSE N14FGAF
Refer to P.14-44.
FUEL PUMP OPERATION CHECK N14FDAG

(2) Check that when the battery voltage is directly applied to
the fuel pump check terminal, the operating sound of the
pump can be heard.
NOTE
Since the high pressure fuel pump is installed in the fuel
tank, its operating sound cannot be readily heard. Remove
the fuel tank cap and listen to the operating sound through
the filler port.
(3) Hold the high pressure fuel hose between your fingers and
I check that the fuel pressure can be felt.
IDLE POSITION SWITCH ADJUSTMENT N14UDA
Caution
The idle position switch has been adjusted by the manu-
facturer.
Do not, therefore, disturb the setting of the idle-position
switch.
If the setting is disturbed as a result of carelessness, or if
the idle-position switch is replaced, make the necessary
setting as described below.
(1) Sufficiently loosen the tension of the accelerator cable.
(2) Disconnect the connector of the idle position switch (fixed
speed adjusting screw).
(3) Loosen the lock nut of the idle position switch (fixed speed
adjusting screw).
(4) Sufficiently loosen the idle position switch by turning it in
the counterclockwise direction and fully close the throttle
valve.
Caution
Be sure to completely close the throttle valve.
(5) Connect a tester (ohm range) between the switch’s
terminal and the body.
(6) Turn down the idle position switch until it enter the “ON”
state where the switch establishes a continuity to body
(this point is called “touch point”). Turn the switch down
15/16 of a turn more from that point.
NOTE
The “touch point” refers to the point where the throttle
valve begins opening.
(7) While holding the idle position switch to make sure that it
does not turn, tighten the lock nut.
(8) Adjust the accelerator cable.
(9) Adjust the basic idle speed. (Refer to P.14-48.)
(lO)Setting the throttle position sensor.
FUEL PRESSURE TEST N14FNAO
(1) Reduce the fuel pressure in the fuel line.

(Refer to P.14-44.)
(2) Disconnect the high pressure fuel hose from the delivery
pipe.
Caution
(3) Remove the throttle body stay.

FUEL SYSTEM - Service Adjustment Procedures <2.0L Enaine> 14-53
(4) Connect a fuel pressure gauge to the special tool (hose

adapter).
Use a suitable O-ring or gasket between the fuel-pressure
gauge and the special tool so as to seal in order to prevent
fuel leakage at this time.
MD998709
MD998742
1
I FU0157
-
(5) Install the special tool, which was set in place in step (4),
between the delivery pipe and the high-pressure fuel hose.
(6) Connect the 0 terminal of the battery.
(7) Apply battery voltage to the fuel pump check terminal and
activate the fuel pump; then, with fuel pressure thus
applied, check to be sure that there is no fuel leakage from
the pressure gauge or the special tool connection part.
(8) Start the engine and run at curb idle speed.

(9) Disconnect the vacuum hose from the pressure regulator
and clog the vacuum hose end. Measure the fuel pressure.
Standard value:
<Non Turbo>330-350 kPa (47-50 psi) at curb idle
<Turbo-M/T> 250-270 kPa (36-38 psi) at curb idle
<Turbo-A/T> 290-320 kPa (41-46 psi) at curb idle
(10)Measure the fuel pressure when the vacuum hose is

connected to the pressure regulator:
Standard value:
<Non Turbo> Approx. 270 kPa (38 psi) at curb idle
<Turbo-M/T> Approx. 190 kPa (27 psi) at curb idle
<Turbo-A/T> Approx. 230 kPa (33 psi) at curb idle
(11)Race the engine repeatedly in two or three series. Then

check that the fuel pressure does not fall when the engine
is running at idle.
(12)Check to be sure that there is fuel pressure in the return
hose also (by gently pressing the fuel return hose with a
finger while repeatedly racing the engine).
NOTE
There will be no fuel pressure in the return hose when the
volume of fuel flow is not sufficient.
(13)lf the results of the measurements made in steps (9) and
(10) above are not within the standard value, use the table
below to determine the probable cause, and then make the
necessary repair.

Fuel pressure too low a. Clogged fuel filter a. Replace fuel filter.
b. Fuel leaking toward return port due to b. Replace fuel pressure regulator.
improper seating of valve in fuel pressure
regulator
c. Low delivery pressure of fuel pump c. Replace fuel pump.
Fuel pressure too high a. Stuck valve in fuel pressure a. Replace fuel pressure regulator.
regulator
b. Clogged or bent fuel return hose or pipe b. Repair or replace hose or pipe.
Fuel pressure with a. Clogged or broken vacuum hose or nipple a. Repair or replace vacuum hose or
vacuum hose connected nipple.
not different from fuel b. Stuck valve in fuel pressure regulator or b. Replace fuel pressure regulator.
pressure with vacuum defective valve seating
hose not connected
(14)Stop the engine and check for change in fuel pressure

gauge indication, which should not drop.
If the gauge indication drops, observe the rate of drop and
determine and remove the causes according to the
following table.
Fuel pressure drops Leakage from injector Replace injector.

slowly after engine is
stopped.
Fuel pressure drops im- Check valve in fuel pump does not close Replace fuel pump.
mediately after engine is
stopped.
(15)Reduce the fuel pressure in the fuel line.

(16)Disconnect the high pressure fuel hose and remove the
fuel-pressure gauge from the delivery pipe.
Caution
(17)Mount a new O-ring in the groove at the end of the high
pressure fuel hose.
(18)Connect the high-pressure fuel hose,,to the delivery pipe

and tighten the screws to the specified torque.
(19)Check for fuel leaks.
@I Apply battery voltage to the fuel pump check terminal
to operate the fuel pump.
@ With fuel pressure acting, check the fuel line for leaks.
EGR VALVE CONTROL VACUUM CHECK NlQFVBBl
Check Condition
(1) Disconnect the vacuum hose from the throttle body EGR
vacuum nipple and connect a hand vacuum pump to the
nipple.
engine speed by racing the engine, vacuum raises pro-
portionately with the rise in engine speed.
NOTE
If there is a problem with the change in vacuum, it is
possible that the throttle body port may be clogged and
A require cleaning.
E
2
li:
>
/ )
Engine speed (rpm) lFU4l6
PURGE PORT VACUUM CHECK N14FVBCl
Check Condition
(1) Disconnect the vacuum hose from the throttle body purge
hose nipple and connect a hand vacuum pump to the
nipple.
engine speed by racing the engine, vacuum remains fairly
constant.
NOTE
If there is no vacuum created, it is possible that the throttle
body port may be clogged and require cleaning.
Engine speed (rpm) 3FU262

14-56 IL SYSTEM
FUE- - MPI~~ Svstem
_ ~-~~~~~ ~,~ InsDection
. 4.8L Enaine>
MPI SYSTEM INSPECTION <1.8L Engine> Nl4PAAM
COMPONENTS LncAT’n”’
Ignition timing adjustment terminal
Fuel ourno check terminal
Air-flow sensor
Intake air temperature sensor
Barometric pressure sensor
Coolant temperature sensor
nhibitor switch (A/T) P

/ xygen sensor
Inhibitor switch
-xT==-TL--==- I OlAO422
FUEL SYSTEM - MPI System Inspection <1.8L Engine>
EGR control solenoid valve [Calif. only]

Purge control solenoid valve ISC servo. Idle Dosition switch, MPS
Purge control -/
Y solenoid valve _
Crankshaft angle sensor, TDC sensor
EGR temperature sensor [Calif. only]

Y-4
16A0802 \ ture sensor

I / OlA0407
\
)n ject 0 r 1 Power steermg fluld pressure switch
ressure switch
14-58 FUEL SYSTEM - MPI System Inspection <1.8L Engine>
MALFUNCTION INDICATOR LIGHT NWQAB
Among the self-diagnosis items, a malfunction indicator light

comes on to notify the driver of the emission control items
when an irregularity is detected.
However, when an irregular signal returns to notmal ‘and the
engine control unit judges that it has returned to normal, the
malfunction indicator light goes out.
Moreover, when the ignition switch is turned off, the light goes
out. Even if the ignition switch is turned on again, the light does
not come on until the irregularity is detected.
Here, immediately after the ignition switch is turn on, the
malfunction indicator light is lit for 5 seconds to indicate that
the malfunction indicator light operates normally.
Items indicated by the lightening malfunction light
Engine control unit

Oxygen sensor
Air-flow sensor
Throttle position sensor
Motor position sensor
Engine coolant temperature sensor
Crank angle sensor
No. 1 cylinder TDC sensor
Ignition timing adjustment signal
Injector
Fuel pump
EGR system <California>
Caution
The malfunction indicator light lights up when the ignition
timing adjustment terminal is short-circuited ,‘t’o ground.
Consequently, it lights up ,when the ignition timing
adjustment is grounded when adjusting ignition timing,
but in this case there is no abnormality.
MALFUNCTION INDICATOR LIGHT INSPECTlON
When turning on the ignition switch, check that the light comes
on.
NOTE
lf the light does not come on, check the harness and light for
breakage.
SELF-DIAGNOSIS Nl4PMFa
The engine control unit monitors the input/output signals

(some signals at all times and the others under specified
conditions) of the engine control unit.
FUEL SYSTEM - MPI System inspection <1.8L Engine> 14-59
When it is noticed that an irregularity has continued for a
--.. specified time or longer from when the irregular signal is
initially monitored. Passing a certain number, the engine
control unit judges that an irregularity has occurred, memorizes
the malfunction code, and outputs the signal to the self-
diagnosis output terminal.
There are 14 diagnosis items, and the diagnosis results can be
read out with a voltmeter.
Moreover, since memorization of the malfunction codes is
backed up directly by the battery, the diagnosis results are
memorized even if the ignition key is turned off. The malfunc-
tion codes will, however, be erased when the battery terminal
or the engine control unit connector is disconnected.
Caution
If the sensor connector is disconnected with the ignition
switch turned on, the malfunction code is memorized. In
this case, disconnect the battery terminal’ (-) for 10
seconds or more, and the diagnosis memory will be
erased.
The 14 diagnosis items are provided as follows, and if plural
items are activated, they are all indicated sequentially from the
smallest code number.
perature sensor
Caution
For the malfunction code of the ignition timing adjustment
signal, the light for the ignition timing adjustment terminal
lights up when short-circuited to ground.
Consequently, it is output when the ignition timing
adjustment is grounded when adjusting ignition timing,
but in this case there is not abnormality.
CHECK PROCEDURE (SELF-DIAGNOSIS) N14PCAEl
Precautions for Operation

(1) When battery voltage is low, no detection of failure is
possible. Be sure to check the battery for voltage and other
conditions before starting the test.
(2) Diagnosis item is erased if the battery or the engine control
unit connector is disconnected. Do not disconnect the
battery before the diagnosis result is completely read.
(3) After check and correction are over, disconnect ground
cable for 10 seconds or more from negative terminal of
battery and connect it again to make sure that failure code
is erased.
14-60 FUEL SYSTEM - MPI Svstem lnwection <1.8L Engine>
INSPECTION PROCEDURE - USING VOLTMETER N14PCAGl
(1) Connect an analogue voltmeter to the self-diagnosis con- ,z

nectar.
(2) Turn ignition switch to ON, and indication of engine control ‘~
unit memory contents will immediately start. If the system
is in normal condition, pointer of voltmeter indicates normal
pattern. If any abnormality is in memory, the pointer of
voltmeter will deflect, indicating abnormal item as de-
scribed in “Diagnosis Chart”.
After recording the abnormal item, check and repair each
part according to the check items in “Diagnosis Chart”.
(3) If the defective parts have been repaired, disconnect the
negative terminal of battery cable for 10 seconds or more
and connect it again to make sure that the abnormal code
7 MPI has been erased.
diagnosis
L Ground
DIAGNOSIS CHART (FAULT TREE) N14PRAC
output Diagnosis code

preference Diagnosis item Check item (Remedy)
order Output signal pattern No. Memory
1 Engrne control - - (ll#ace engine control

unit
:1 12A0104
2 Oxygen sensor 11 Retained l Harness and connector

l Fuel, pressure
l Injectors
(Replace if defective)
l Intake air leaks
12A0104 0 Oxygen sensor
3 Air flow sensor 12 Retained l Harness and connector

(If harness and connector
are normal, replace air
flow sensor assembly.)
12A0104
4 Intake air
temperature sensor
12A0104
5 Throttle position 14
sensor
:JJlJJ-- 12A0104
6 Motor position 15
sensor
L II
12A0104
FUEL SYSTEM - MPI System Inspection <1.8L Engine>

reference Diagnosis item Check item (Remedy)
7 Engine coolant Retained l Harness and connector

temperature sensor l Engine coolant temper-
ature sensor
:-rlrLn- 2’
12A0107
8 Crank angle sensor Retained l Harness and connector

are normal, replace
:nn 22 distributor assembly.)
12A0107
9 No. 1 cylinder top Retained l Harness and connector

dead center sensor H (If harness and connector
are normal, replace
Lnn 23 distributor assembly.)
12A0107
10 Vehicle speed sensor 24 Retained l Harness and connector

(reed switch) H l Vehicle speed sensor
(reed switch)
L u 1 nnJln
12A0107
11 Barometric pressure 25 Retained l Harness and connector

sensor H (If harness and connector
are normal, replace
L u I nl-uvln barometric pressure
12A0107 sensor assembly.)
12 Ignition timing adjust- 36 - l Harness and connector

ment signal H
L UUI nluvuuL
12R0468
13 Injector Retained l Harness and connector

0 Injector coil resistance
:m 41
12A0105
UUUI nn
14 Fuel pump 42 Retained l Harness and connector
H 0 Control relay
L
12A0105
15 EGR <California> 43 Retained l Harness and connector
u u u u-inn
l EGR temperature sensor
H l EGRvalve
l EGR valve control sole-
L noid valve
12A0105 l EGR valve control vacuurr
n
16 Normal state - - -
H
L
12A0104
NOTE
Replace the engine control unit if a malfunction code is output although the inspection reveals that there is no problem with the check
items.
INTAKE AIR TEMPERATURE SENSOR NlmNAB
Air flow sensor
side connector INSPECTION
(1) Disconnect the air flow sensor connectors.
(2) Measure resistance between terminals @ and @.
Temperature “C PF) Resistance kR

0 (32) 6.0
20(68) 2.7
6FUO622
80(176) 0.4

drier.
Temperature “C (“F) Resistance kfi

Higher Smaller
(4) If the value deviates from the standard value or the

resistance remains unchanged, replace the air flow sensor
assembly.

NWQABE
INSPECTION
(1) Remove engine coolant temperature sensor from the
intake manifold.
(2) With temperature sensing portion of engine cool?nt
temperature sensor immersed in hot water, check resist-
ance.
16R1251
Temperature “C (“F) Resi’stance kQ
0 (32) 5.9
20(68) 2.5
40 (104) 2.7
80(176) 0.3
(3) If the resistance deviates from the standard value greatly,

replace the sensor.
INSTALLATION
(1) Apply specified sealant to threaded portion and tighten to
specified torque.
or equivalent
Specified torque: 20 - 40 Nm (15 - 29 ftlbs.)
(2) Fasten harness connectors securely.
FUEL SYSTEM - MPI Svstem Inspection <1.8L Engine> 18-63
Throttle position sensor

THROITLE POSITION SENSOR Nl4OBBKa
INSPECTION
Ground (1) Disconnect the throttle position sensor connector.
(2) Measure resistance between terminal @I (sensor ground)
output and terminal @ (sensor power).
Sensor Standard value: 3.5-6.5 kGI
power
SUPPlY (3) Connect a pointer type ohmmeter between terminal @
(5V) (sensor ground) and terminal @ (sensor output).
(4) Operate the throttle valve slowly from the idle position to
1 FUO507 the full open position and check that the resistance changes
smoothly in proportion with the throttle valve opening
angle.
(5) If the resistance is out of specification, or fails to change
smoothly, replace the throttle position sensor.
Throttle position sensor installation torque:
1.5 - 2.5 Nm (1.1 - 1.6 ftlbs.)
6FU1244
IDLE POSITION SWITCH N14QKADa
INSPECTION
(1) Disconnect the connectors of the motor position sensor.
Motor Dosition sensor connector (2) Check the continuity between terminal @ and the body
(motor ‘side, front view) ground.
I Accelerator pedal I Continuity I

Depressed I Non-conductive (@J fl) I
Released I Conductive (0 fl) I
T (3) If defective, replace the idle speed control servo assembly.

6FU1247
Motor position sensor MOTOR POSITION SENSOR N140lAJ

connector
(motor side, front view) INSPECTION
(1) Disconnect the motor position sensor connector.
(2) Measure the resistance between terminals @ and 0.
Standard value: 4 - 6 kfi
6FU1252
Idle speed control (3) Disconnect the idle speed control servo connector.
servo connector (4) Connect DC 6V between terminals @) and @ of the idle
speed control servo connector, and then measure the
resistance between terminals @ and @ of the motor
position sensor connector when the idle speed control
servo is activated (caused to expand and contract).
Standard value: Smooth increase/decrease in accord-
ance with extension and retraction of
idle speed control servo plunger.
Caution
Apply only a 6V DC or lower voltage. Application of
higher voltage could cause locking of the servo gears.
(5) If there is a deviation from the standard value, or if the
change is not smooth, replace the idle speed control servo
assembly.
OXYGEN SENSOR N14QDBAb
INSPECTION
Caution
1. Before checking, warm up the engine until engine
coolant temperature reaches 85 to 95°C (185 to 205°F).
2. Use an accurate digital voltmeter.
(1) Disconnect the oxygen sensor connector and connect a
voltmeter to the oxygen sensor connector.
(2) While repeating engine racing, measure the oxygen sensor
output voltage.
Engine Oxygen sensor Remarks

output voltage
Race 0.6- 1 .OV Make air-fuel mixture

rich by accelerator
operation
6FU098t
NOTE
For removal and installation of the oxygen sensor, refer to
GROUP 11 - Exhaust Manifold.
Oxygen sensor installation torque:
40 - 50 Nm (30 - 36 klbs.)
EGR TEMPERATURE SENSOR <California> NIIRCHA~
Refer to GROUP 25 - Exhaust Gas Recirculation System.
VEHICLE SPEED SENSOR N14QEEBa
Refer to GROUP 8 - Meters and Gauges.
AIR CONDITIONER SWITCH N14QQABa
Refer to GROUP 8 - Column Switch.

FUEL SYSTEM - MPI Svstem InsDection <1.8L Engine> 14-65
INHIBITOR SWITCH N14QRACs
Refer to GROUP 21 - Service Adjustment Procedures.
POWER STEERING OIL PRESSURE SWITCH

N14flCJB
Refer to GROUP 19 for power steering system inspection.
INJECTORS N14QTAG
CHECKING OPERATION SOUND

Using a sound-scope, check the operation sound (“chi-chi-chi”)
of injectors during idling or during cranking.
Check that as the rotating speed increases, the frequency of
the operating sound also increases.
Caution
Note that even if the injector you are checking is not
operating, you will hear the operating sound of the other
3FUO349 injectors.
NOTE
If no operating sound is heard from the injector that is being
checked, check the injector drive circuit. If there is nothing
wrong with the circuit, a defective injector or engine control
/--
unit is suspected.
MEASURING RESISTANCE BETWEEN TERMINALS

(1) Remove the injector connector.
(2) Measure the resistance between the terminals.
Standard value: 13 - 16 L(Z [at 20°C (68”F)I
(3) Install the injector connector.
’ 3FU03991
IDLE SPEED CONTROL SERVO NlQQUAAb
Idle speed control INSPECTION

servo connector
(motor side, front view) (1) Disconnect the idle speed control servo connector.
(2) Check continuity of the idle speed control servo coil.
I Measuring terminals I Continuity I

@ - @ Conductive 5 to 35 fi resistance
a t 20°C (68°F)
3FUO393
14-66 FUEL SYSTEM - MPI System Inspection 4.8L Engine>
(3) Connect 6V DC between terminal @ and terminal @ of the
idle speed control servo connector, and check to be sure
that the idle speed control servo operates.
Caution
Apply only a 6V DC or lower voltage. Application of
higher voltage could cause locking of the servo gears.
(4) If not, replace idle speed control servo as an assembly.
6FU1253
CONTROL RELAY NWWAE
INSPECTION
(1) Remove the control relay.
(2) Inspect the continuity between the control relay terminals.
Inspection terminals Continuity
l---$+-l Yes (approx. 9552)

~~~
B-0 Yes (approx. 35Q)
- 1 Batterv @-@ Yes in 1 direction only
(3) Use jumper wires and connect control relay terminal @ to

the battery @ terminal and terminal @ to the battery @
terminal.
Caution
Be very careful when connecting the jumper wires
because the relay will be damaged if a mistake is made
I with the contact terminals.
6FUO751
(4) With the battery 0 terminal jumper wire connected and
disconnected, check the continuity between control relay
terminals @-@I.
Continuity between terminals 0-B
(5) Use jumper wires to connect control relay terminal @I to

the battery @ terminal and terminal @ to the battery 0
03AOO50
terminal.
(6) With the battery 0 terminal jumper wire connected and
disconnected, check the continuity between control relay
terminals @-@I.
1 Continuity between terminals 0-a
(7) Replace the control relay if faulty.

03AOO57
FUEL SYSTEM - MPI System Inspection <1.8L Engine> 14-67
POWER TRANSISTOR NlQRCGA
Refer to GROUP 8 - Ignition System
AIR CONDITIONER POWER RELAY N14RCLB
Refer to GROUP 24 - Air Conditioner.
PURGE CONTROL SOLENOID VALVE N14RCKA
Refer to GROUP 25 - Evaporative Emission Control System.
EGR CONTROL SOLENOID VALVE <California>

N14RCLA

14-68 FUEL SYSTEM - MPI System Inspection <2.0L DOHC Engine>
MPI SYSTEM INSPECTION <2.0L DOHC N14PAAN
COMPONENTS LOCATION
<Non-Turbo> Ignition timing adjustment terminal
Throttle Dosition sensor Fuel pump check terminal
Fuel pump check
I /B \ Q-terminal \
ustment terminal
Crankshaft angle sensor

‘DC sensor
ir-flow sensor
take air temperature sensor
arometric pressure sensor nhibitor switch (A/T only)
OlA040i
FUEL SYSTEM - MPI System Inspection <2.0L DOHC Engine>

Purge control solenoid valve
1
/AF--Y:r
Ignition coil, Power transistor
Power steering fluid Dressure switch
Oxygen sensor Coolant temDerature sensor

<Turbo> I nition timing adjustment terminal

Throttle position sensor 9uel pump check terminal
tm\ m
24-T. \/ \ - - - - F u e l pump check
Waste aate control valve [Turbo only1
I O;A0455
Air-flow sensor
Barometric Dressure sensor
1 (built in intake air ’ Y / I

I iemperature sensor and
barometric pressure sensor) L sensor

Purge control solenoid valve
Injector Fuel pressure control valve [Turbo only]
Purge control Fuel pressure

II solenoid valve control valve
solenoid valve
II 01A0499 0110503
Ignition coil, Power transistor

I
Detonation sensor
\’ 16A0803
\
Oxvnen sensor \ Power steering fluid oressure switch
14-72 FUEL SYSTEM - MPI Svstem InsDection <2.0L DOHC Engine>
MALFUNCTION INDICATOR LIGHT
Among the self-diagnosis items, a malfunction indicator light
comes on to notify the driver of the emission control items
when an irregularity is detected.
However, when an irregular signal returns to normal and the
engine control unit judges that it has returned to normal. the
malfunction indicator light goes out.
Moreover, when the ignition switch is turned off, the light goes
out. Even if the ignition switch is turned on again, the light does
not come on until the irregularity is detected.
Here, immediately after the ignition switch is turn on, the
malfunction indicator light is lit for 5 seconds to indicate that
the malfunction indicator light operates normally.
I- -l
Items indicated by the lightening malfunction light
Engine control unit

Oxygen sensor
Air flow sensor
klfunction Throttle positron sensor

indicator light
Engrne coolant temperature sensor
Crank angle sensor
Top dead center sensor /

Detonatron sensor <Turbo>
Injector
Fuel pump
EGR <California>
Ignition co11
i
MALFUNCTION INDICATOR LIGHT INSPECTION
When turning on the ignition switch, check that the light comes
on.
NOTE
If the light does not come on, check the harness and light for
breakage.
FUEL SYSTEM - MPI System Inspection <2.0L DOHC Engine> 14-73
SELF-DIAGNOSIS N14PAAE
The engine control unit monitors the input/output signals

(some signals at all times and the others under specified
conditions) of the engine control unit.
When it is noticed that an irregularity has continued for a
specified time or longer from when the irregular signal is
initially monitored. Passing a certain number, the engine
control unit judges that an irregularity has occurred, memorizes
the malfunction code, and outputs the signal to the self-
diagnosis output terminal.
There are 14 diagnosis items, and the diagnosis results can be
read out with a voltmeter.
Moreover, since memorization of the malfunction codes is
backed up directly by the battery, the diagnosis results are
memorized even if the ignition key is turned off. The malfunc-
tion codes will, however, be erased when the battery terminal
or the engine control unit connector is disconnected.
Caution
If the sensor connector is disconnected with the ignition
switch turned on, the malfunction code is memorized. In
this case, disconnect the battery terminal (-) for 10
seconds or more, and the diagnosis memory will be
erased.
The 14 diagnosis items are provided as follows, and if plural
items are activated, they are all indicated sequentially from the
smallest code number.
arometnc pressure sensor
CHECK PROCEDURE (SELF-DIAGNOSIS) N14PCAE2
Precautions for Operation

(1) When battery voltage is low, no detection of failure is
possible. Be sure to check the battery for voltage and other
conditions before starting the test.
(2) Diagnosis item is erased if the battery or the engine control
unit connector is disconnected. Do not disconnect the
battery before the diagnosis result is completely read.
(3) After check and correction are over, disconnect ground
cable for 10 seconds or more from negative terminal of
battery and connect it again to make sure that failure code
is erased.
FUEL SYSTEM - MPI Svstem InsDection <2.0L DOHC Engine>
INSPECTION PROCEDURE - USING VOLTMETER N14PCAGZ
(1) Connect an analogue voltmeter to the self-diagnosis con-

nector.
(2) Turn ignition switch to ON, and indication of engine control
unit memory contents will immediately start. If the system
is in normal condition, pointer of voltmeter indicates normal
pattern. If any abnormality is in memory, the pointer of
voltmeter will deflect, indicating abnormal item as de-
scribed in “Diagnosis Chart”.
After recording the abnormal item, check and repair each
part according to the check items in “Diagnosis Chart”.
(3) If the defective parts have been repaired, disconnect the
negative terminal of battery cable for 10 seconds or more
and connect it again to make sure that the abnormal code
MPI has been erased.
diagnosis
I Ground
DIAGNOSIS CHART (FAULT TREE) NlQPRAD

Ireference Dragnosrs Item - C h e c k i t e m (Remedy)
1 Engine control : I- - W$$ace engine control

unit
12A0104
2 Oxygen sensor 11 Retained l Harness and connector

0 Oxygen sensor
o Fuel pressure
0 Injectors
: - J - l - J - (Replace if defective)
12A0104 l Intake air leaks
3 Air flow sensor Retained l Harness and connector

are normal, replace air
:-rLJL ‘* flow sensor assembly.)
12A0104
4 Intake au Retarned l Harness and connector

temperature sensor H l Intake air temperature
sensor
J--lNlL l3
12A0104
5 Throttle postron Retained l Harness and connector

sensor l Throttle position sensor
:n l4
17A0104
6 Engine coolant Retained l Harness and connector

temperature sensor l Engine coolant temper-
ature sensor
:nn 2’
12A0107
FUEL SYSTEM - MPI Svstem InsDection <2.0L DOHC Engine>

Ireference Dragnosrs Item Check item (Remedy)
7 Crank angle sensor Retained l Harness and connector

are normal, replace crank
:nn ** angle sensor assembly.)
12A0107
8 Top dead center Retained l Harness and connector

sensor (No.1 and (If harness and connector
No. 4 cylinder) are normal, replace crank
:- 23 angle sensor assembly.)
12A0107
9 Vehicle speed sensor 24 Retained l Harness and connector

(reed swatch) H l Vehicle speed sensor
(reed switch)
L I u I nlvln
12A0107
10 Barometnc pressure 25 Retained l Harness and connector

sensor H (If harness and connector
are normal, replace
L ULllnMll barometric pressure
12A0107 sensor assembly.)
11 Detonation sensor Retained l Harness and connector

<Turbo> l Detonation sensor
:m 31
12R0468
12 Injector Retained l Harness and connector

0 Injector coil resistance
:m 41
12A0105
UUUI nn
13 Fuel pump 42 Retained l Harness and connector
H 0 Control relay
L
12A0105
14 EGR <California> 43 Retained l Harness and connector
u u u I nnn
l EGR temperature sensor
H l EGRvalve
l EGR valve control sole-
L noid valve
12A0105 l EGR valve control vacuum
15 Ignition coil 44 Retained l Harness and connector

H 0 Ignition coil
0 Power transistor
L UUUL-llMlL
12A0105
16 Normal state - - -
H
L
12A0104
NOTE
Replace the engine control unit if a malfunction code is output although the inspection reveals that there is no problem with the check
items.
14-76 FUEL SYSTEM - MPI Svstem InsDection <2.0L DOHC Enaine>
<Non-Turbo>
INTAKE AIR TEMPERATURE SENSOR Nl4OHAB
Air flow sensor INSPECTION

srde connector (1) Disconnect the air flow sensor connectors.
(2) Measure resistance between terminals @ and @I <Non-
Turbo>
(3) Measure resistance between terminals @and @I <Turbo>
Temperature “C (“F) Resistance kR

0 (32) 6.0
6FUO622
20 (68) 2.7
<Turbo> 80 (176) 0.4
6FUO623

drier.
Temperature “C (“F) Resistance k0

Higher Smaller
(5) If the value deviates from the standard value or the

resistance remains unchanged, replace the air flow sensor
assembly.

NlMABEl
INSPECTION
(1) Remove engine coolant temperature sensor from the
intake manifold.
(2) With temperature sensing portion of engine coolant
temperature sensor immersed in hot water, check resist-
ance.
16Rl251 Temperature “C (“F) Resistance kfl

0 (32) 5.9
20 (68) 2.5
40 (I 04) 2.7
80 (I 76) 0.3
(3) If the resistance deviates from the standard value greatly,

replace the sensor.
FUEL SYSTEM - MPI Svstem InsDection <2.0L DOHC Engine> 14-77
INSTALLATION
(1) Apply specified sealant to threaded portion and tighten to
specified torque.
Specified sealant: MOPAR Part No.4318034 or
equivalent
Specified torque: 20 - 40 Nm (15 - 29 ft.lbs.1
(2) Fasten harness connectors securely.
THROTTLE POSITION SENSOR N14QBBKl
INSPECTION
(1) Disconnect the throttle position sensor connector.
(2) Measure resistance between terminal @I (sensor ground)
and terminal @ (sensor power).
Standard value: 3.5 - 6.5 kR
(3) Connect a pointer type ohmmeter between terminal @I

(sensor ground) and terminal @ (sensor output).
(4) Operate the throttle valve slowly from the idle position to
the full open position and check that the resistance changes
smoothly in proportion with the throttle valve opening
angle.
6FU1244
(5) If the resistance is out of specification, or fails to change

smoothly, replace the throttle position sensor.
Throttle position sensor installation torque:
1.5 - 2.5 Nm (1.1 - 1.8 ft.lbs.)
IDLE POSITION SWITCH N14QKAEa
INSPECTION
(1) Keeping the acceleration pedal released, check that the
throttle valve lever or the idle position switch is pushed.
NOTE
If it is not pushed, adjust the idle position switch (fixed
speed adjusting screw). (Refer to P.14-52.)
(2) Disconnect the idle position switch connector.
(3) Check the continuity between terminal @) to the ground.
J II\ / hFU1419
Accelerator pedal Continuity .
Depressed Non-conductive (03 fl)
Released I Conductive (0 fl) I
(4) Replace the idle position switch if faulty.

NOTE
For replacement procedure, refer to the idle position switch
(fixed speed adjusting screw) adjustment section (P.14-
52.).
OXYGEN SENSOR NllQDeJ
INSPECTION
(1) Disconnect the oxygen sensor connector.
(2) Check that there is continuity [approx. 12 52 at 20°C (68”F)l
between oxygen sensor connector terminal @ and terminal
GO.
(3) If there is no continuity, replace the oxygen sensor.
(4) Warm up the engine until the engine coolant temperature
exceeds 80°C (176°F).
(5) Use jumper wires to connect oxygen sensor terminal @
and terminal @ to the battery @ terminal and 0 terminal.
Caution
because the oxygen sensor will be damaged if a
mistake is made in the connecting terminals.
(6) Connect a digital voltmeter between terminal @ and
terminal 0.
(7) While repeatedly racing the engine, measure the ‘output
voltage of the oxygen sensor.
6FUO999
When racing When the air/fuel mixture ratic

engine
INSTALLATION
1. For removal and installation of oxygen sensor, refer to
GROUP 11 - Exhaust Manifold.
2. Oxygen sensor tighten to specified torque.
Specified torque: 40 - 50 Nm (29 - 36 ft.lbs.)
FUEL SYSTEM - MPI System Inspection <2.0L QOHC Engine> 14-79
EGR TEMPERATURE SENSOR N14RCHAa
VEHICLE SPEED SENSOR N140EBBa
Refer to GROUP 8 - Meters and Gauges.
AIR CONDITIONER SWITCH Nl4QQAEa
Refer to GROUP 8 - Column Switch.
POWER STEERING OIL PRESSURE SWITCH

N14RCJB
Refer to GROUP 19 for power steering system inspection.
INJECTORS NWXAH
CHECKING OPERATION SOUND

Using a sound-scope, check the operation sound (“chi-chi-chi”)
of the injectors during idling or during cranking.
Check to be sure that the operation sound increases when the
engine speed is increased.
Caution
Note that the sounds of other injectors may be heard even
though the injector being checked is not operating, so care
must be taken when checking.
NOTE
If the operation sounds cannot be heard, check the injector
activation circuit.
If this circuit is normal, there is probably a malfunction of the
injector or of the engine control unit.
MEASURING OF RESISTANCE BETWEEN TERMINALS
(1) Disconnect the connector for the injectors.
(2) Measure the resistance between terminals.
Standard value:
<Non-Turbo> 13 - 1 6 S2 [at 20°C (68”F)]
<Turbo> 2 - 3 52 [at 20% (68”F)]
(3) Connect the connector for the injectors.
IDLE SPEED CONTROL SERVO N14QUAD
CHECKING OPERATING SOUND

(1) Check that when the ignition switch is placed in the ON
position (the engine not started), the operating sound of the
stepper motor can be heard over the idle speed control
servo.
(2) If no operating sound can be heard, check the stepper
motor drive circuit.
(If the circuit is good, a defective stepper motor or engine
control unit is suspected.)
14-80 FUEL SYSTEM - MPI System Inspection <2.0L DOHC Enginh
CHECKING COIL RESISTANCE
(1) Disconnect the idle speed control servo connector.
(2) Measure the resistance between terminals @ and @ or
between terminals @and @ of the idle speed control servo
connector.
Standard resistance: 28 - 33 fl [at 20°C (68”F)l
(3) Measure the resistance between terminals @ and @ or
between terminals @ and @ of the idle speed control servo
connector.
Standard resistance: 28 - 33 LR [at 20°C (68”F)]
7FUOOlO
OPERATION CHECK
(1) Remove the throttle body.
(2) Remove the stepper motor.
6FU1426
(3) Apply voltage as indicated below and check for presence/

absence of vibration due to stepper motor operation.
1. Connect the positive terminal of the power supply
(about 6V) to terminals @ and @ of the connector.
2. Connect the negative terminal of the power supply to
terminals @ and @.
3. Connect the negativeterminal to terminals @ and @.
4. Connect the negative terminal to terminals @ and @.
7. Connect the terminals in sequence from step 6 to 2.
(4) If vibration is felt as a result of the inspections, the stepper
motor can be judged as normal.
7FUOOll
FUEL SYSTEM - MPI System Inspection <2.0L DOHC Engine> 'I4181
CONTROL RELAY NWWAC
_- INSPECTION
(1) Remove the control relay.
(2) Use jumper wires and connect control relay terminal @I to
terminal.
Caution
because the relay will be damaged if a mistake is made
with the contact terminals.
(3) With battery 0 terminal jumper wire connected and
disconnected, measure the voltage at control relay termi-
nals @I and 0.
(4) Use jumper wires to connect control relay terminal @ to

OlLO22Z the battery @ terminal and terminal @ to the battery 0
terminal.
(5) With the battery @ terminal jumper wire connected and
disconnected, measure the voltage at control relay termi-
nals @I and 0.
Continuity between terminals 0-0

)
(6) Use jumper wires and connect control relay terminal @ to

terminal.
(7) With the battery 0 terminal jumper wire disconnected,
measure the voltage at control relay terminal 0.
31
(8) Replace the control relay if faulty.

POWER TRANSISTOR NlIAcQAl
Refer to GROUP 8 - Ignition System a-4
AIR CONDITIONER POWER RELAY N14NCl.a -
Refer to GROUP 24 - Air Conditioner.
PURGE CONTROL SOLENOID VALVE N14RCKA
Refer to GROUP 25 - Evaporative Emission Control System.
EGR CONTROL SOLENOID VALVE <California>

N14NCU
FUEL PRESSURE CONTROL VALVE <Turb$z*

OPERATIONAL CHECK
NOTE
Before the vacuum hoses are removed, make a mark’on the -
hose for visual identification so that they can be reconnected in ,
their original positions.
(1) Remove the vacuum hoses (blue stripes and black) from
the solenoid valve.
(2) Disconnect the harness connector.
\ \ \I \ 3FUO352
(3) Apply vacuum with a hand vacuum pump to the nipple to

which the black vacuum hose was connected and check for
air tightness both when a voltage is applied to the solenoid
valve terminal and when the voltage is removed.
Battery voltage Other nipple of Normal condition

solenoid valve
When voltage Open Vacuum leaks
is removed
,\ Blocked by finger Vacuum is retained
\ \I \
3FUO353
When voltage Open Vacuum is retained
is applied
CHECKING COIL RESISTANCE

Measure the coil resistance with a tester.
Standard resistance: 36 - 46 R [at 20°C (68”F)]
,\ ‘\R /
\ \ \I \ 3FUo354
FUEL SYSTEM - Injector 14-83
INJECTOR
NWSA-A
* ‘- REMOVAL AND INSTALLATION
l Measurement of Fuel Pressure
(Refer to P.14-44. 52.)
4.8L Engine>
4-6 N m
3-4 ft.lbs.
lo-13 Nm
7 - 9 ft.lbs.
7-11 N m -
hl ft.lbs. -zF!
<2.0L DOHC Engilme> 11

R 03AO190
;533i5,b;m
- . .
71s-Y-
4-6 N m
a-3-4 ft.lbs.
Center cover
03AOlSS
::, Connection for control harness
d -- -
4* 12: Delivery pipe
13. Insulator
Removal steps 14. Insulator
** l + 15. Injector
1. Connection for breather hose H 16. O-ring
2. Connection for PCV hose l + 17. Grommet
+e *+ 3. Connection for high pressure fuel hose
4. O-ring
6. Connection for fuel return hose !PTkeverse the rem&al procedures to reinstall.
l + 7. Fuel pressure regulator (2) +* : Refer to “Service Points of Removal”.
8. O-ring (3) l * : Refer to “Service Points of Installatron”
9. Accelerator cable clamp (4) m : Non-reusable parts
14-84 FUEL SYSTEM - Injector
SERVICE POINTS OF REMOVAL H4s0m1‘~
3. DISCONNECTION OF THE HIGH PRESSURE FlJFL HOSE /;;
Bleed the residual pressure within the fuel pipe line’& as to ~
prevent the flow of fuel.
For information concerning the method to be folfowed for
bleeding the residual pressure, refer to P.14-44.
Caution
Cover the hose connection with rags to prevent splash,
of fuel that could be caused by some residual pressure
12. REMOVAL OF DELIVERY PIPE/ 15. INJECTOR
Remove the deliver-y pipe (with the injectors attached to it).
Caution
Care must be taken, when removing the delivery pipe,
not to drop the injector.
INSPEiZTION N14NGAA
INJECTORS
(1) Measure resistance between terminals of injector using a
circuit tester. +-%
Standard value: /
13-1652 [at 20°C (68”F)] <1.8L Engine, 2.0L DOHC
Engine (NoniTurbo)>
2-3Q [at 20°C (68”F)] <2.0L DOHC Engine (Turbo)>
(2) If the resistance is out of specification, replace the injector.
SERVICE POINTS OF INSTALLATION N14SDAEl’
17. INSTALLATION OF GROMMET/lG. 0-RINGI15. IN-

JECTOR
(I) After installation of the grommet and O-ring (in that
sequence) to the injector, apply light oil or petrol to the
O-ring.
03*0095
(2) While turning the injector to.the left and right, install it
to the delivery pipe.
(3) Check to be sure that the injector turns smoothly.
Caution
If it does not turn smoothly, the O-ring may be ~
trapped remove the injector and then re-insert it
into the delivery pipe and check once again. L
Delivery pipe
03A0095
-
FUEL SYSTEM - Injector/Throttle Body <1.8L Engine> 14-85
Delivery pipe 7. INSTALLATION OF FUEL PRESSURE REGULATOR
When connecting the fuel-pressure regulator to the deliv-
ery pipe, apply light oil or petrol to the O-ring, and then
insert, being careful not to damage the O-ring.
Fuel pres
regulator
O-ring
3. CONNECTION OF THE HIGH PRESSURE FUEL HOSE

Y pipe When connecting the high pressure fuel hose to the
delivery pipe, apply petrol to the hose union, and then
insert, being careful not to damage the O-ring.
O-kg
OWOO79
THROTTLE BODY 4.8L Engine>

Removal steps
l 4 1. Connection for accelerator cable 03AO277
2. Connection for breather hose
5. Connection for ISC motor connector
6. Connection for TPS connector
7. Connection for MPS connector
8. Connection for water hose NOTE
9. Connection for water by-pass hose (1) Reverse the removal procedures to reinstall.
10. Throttle body (2) I)+ : Refer to “Service Points of Installation”.
l 4 11. Gasket (3) m : Non-reusable parts
14-86 FUEL SYSTEM - Throttle Bodv 4.8L Enaine>
SERVICE POINTS OF INSTALLATION Nl4sDAM
11. INSTALLATION OF GASKET .a
Install the gasket so that the projection is where shown in ‘_
the figure.
Caution
Poor idling, etc. may result if the gasket is installed
incorrectly.
1. ACCELERATOR CABLE ADJUSTMENT
Air intake For information concerning adjustment of the accelerator
plenum side I
cable, refer to P.14-106.
DISASSEMBLY AND REASSEMBLY N14SE-A
1.5-2.5 Nm /’
1.1
6FU1292
Disassembly steps
I)4 1. Throttle position sensor
2. Idle speed control servo assembly
3. Throttle valve set screw
4. Throttle body
NOTE
SERVICE POINTS OF DISASSEMBLY N14SFAE
Caution
1. When loosening a Phillips screw which has been firmly
tightened, use a Phillips screwdriver that is an exact fit
for the screw. ,&
2. Do not remove the throttle valve.
3. Be careful when removing the throttle position sensor
screw as it has been coated with adhesive.
FUEL SYSTEM - Throttle Bodv <1.8L Engine>
Throttle position INSPECTION N14SHAC4

sensor connector
THROTTLE POSITION SENSOR CONTINUITY CHECK
(1) Measure resistance between terminals @ and @ of the
throttle position sensor using a circuit tester.
Standard value: 3.5-6.5 kSZ
(2) Check sensor body for cracks and damages.
6FU1398
I
IDLE SPEED CONTROL SERVO CONTINUITY CHECK
Measure resistance between terminals @and @ using a circuit
tester.
Standard value: 5-35 Q [at 20°C (68”F)I
control servo
connector
6FU1277
I IDLE SPEED CONTROL SERVO OPERATION INSPECTION

Caution
Apply only a 6V DC or lower voltage. Application of higher
voltage could cause locking of the servo gears.
(1) Connect 6V DC to terminals @ and @ and check that the
idle speed control servo extends and retracts by itself.
Idle speed control

servo motion
I
I When terminal @ is @ ( Retracts I
I When terminal @ is @ ) Extends I
(2) If the idle speed control servo does not move, replace the
idle speed control servo assembly.
THROTTLE BODY COMPONENTS CLEANING

(1) Clean all components, but the following components must
not be cleaned by using a cleaning agent.
l Idle speed control servo assembly
The insulation of these components will be damaged if they
are immersed in a cleaning agent. They should be cleaned
by using only a piece of cloth.
(2) Check for clogging of the vacuum port or passage. Clean
the vacuum passage by using compressed air.
14-88 FUEL SYSTEM - Throttle Body 4.8L Engine>
SERVICE POINTS OF REASSEMBLY N14SGADa
1. INSTALLATlON.OF THROlTLE POSITION SENSOR H

(1) Install throttle position sensor on throttle body and
,
temporarily tighten screw.
Caution
Adjust the throttle position sensor and idling speed
control according to the engine load condition.
(2) Check correct installation of the throttle position sen-

Throttle position
sor. While moving the throttle lever in both open and
round
close directions, that resistance between terminals @
and @ or @ and @ changes. If resistance changes
smoothly, the throttle position sensor has been instal-
led correctly.
sensor output
7FUO535
AFTER REASSEMBLY INSPECTION

Motor position IDLE POSITION SWITCH CONTINUITY CHECK
sensor connector
(1) Using a circuit tester, check continuity between the body
and terminal @I when the throttle valve is fully closed and ,ri
when fully opened.
Throttle valve I Continuity I

Fully closed Conductive
6FU1247 Fully opened Non-conductive
(2) If otherwise than shown above, replace the idle speed

control servo assembly.
FUEL SYSTEM - Throttle Body <2.0L DOHC Engine>
THROTTLE BODY Ml3s&c

sr REMOVAL AND INSTALLATION
<Non-Turbo>
11-16 ft.lbs.
Removal steps
1. Connection for accelerator cable
2. Connection for breather hose
4. Connection for air hose C
6. Connection for ISC motor and idle switch
connector
7. Connection for TPS connector
8. Connection for water hose 03A0285
9. Connection for water by-pass hose
10. Ground plate mounting screw
11. Throttle body stay and ground plate
12. Air fitting
13. Gasket !Fbeverse the removal procedures to reinstall
14. Throttle body (2) l + : Refer to “Service Points of Installation”.
l * 15. Gasket (3) m : Non-reusable parts
14-90 FUEL SYSTEM - Throttle Body <2.0L DOHC Engine>
r
SERVICE POINTS OF INSTALLAtlON Nl49DAU
15. INSTALLATION OF GASKET G

Install the gasket so that the projection is where shown in ._
the figure.
Caution
Poor idling, etc. may result if the gasket is installed
incorrectly.
Air intake
plenum side 03AO259
J
DISASSEMBLY AND REASSEMBLY Nl49C9
2.5-4.5 Nm
1.8-3.3 ft.lbs.
1.5-2.5 Nm
1.1-1.8 ftlbs.
MU1427
Disassembly steps
1. Throttle position sensor
2. Idle position speed control servo
3. Idle position switch
4. Adjusting nut
5. Throttle body
NOTE
Reverse the disassembly procedures to reassemble.
FUEL SYSTEM - Throttle Bodv <2.0L DOHC Erwini+
SERVICE ~POINTS OF DISASSEMBLY Nl4SFAF
i Caution
1. When loosening a Phillips screw which, has been firmly
tightened, use a Phillips screwdriverthat is an exact fit
for the screw.
2. Do not remove the throttle valve. ”
3. Be careful when removing the throtite pos?ion sensor
screw and the idle speed control servo- screw as they
have been coated with adhesive.
INSPECTION Nl4SNAB
THROTTLE POStTlON SENSOR CONTtNUlTY TEST

(1) Using a circuit tester, measure the resistance beween
terminal @ and terminal @ of the throttle position sensor
connector.
Standard resistance: 3.5-6.5 k&2
6FU1244 I
(2) While the circuit tester is connected to terminals @ and @,

or @ and @ of the throttle position sensor connector,
slowly operate the throttle valve until it is at its maximum
Ground
open position and check that the resistance changes
Throttle smoothly.
position
sensor
output
Throttle
position
sensor
power-
source 6FUO7X
tDLE SPEED CONTROL SERVO CONTINUITY CHECK

Measure the resistance between each of the terminals.
Standard resistance:
Between terminal @ and either terminal
0 or 0 28-33 Q [at 29X t6WF)l
Between terminal 0 and either terminal
@ or @I 28-33 P [at 20°C (68”F)l
7FUOOlO
14-92 FUEL SYSTEM - Throttle Bodv <2.0L DOHC Engine>
tDLE SPEED CONTROL SERVO OPERATIONAL CHECK
(1) Connect the positive terminal of a DC power supply of ~
approx. 6V to terminals @ and @ of the idle speed control .
servo connector. /
(2) Holding the idle speed control servo as indicated in the
illustration, connect the negative terminal of the power
supply to each pair of its terminals in the order given below,
and ascertain whether or not small vibration is created due
to the operation of the stepper motor.
0 Connect the negative terminal of the power supply to
terminal @ and terminal @.
@ Connect the negative terminal of the power supply to
terminal @ and terminal @I.
Iw-- @I Connect the negative terminal of the power supply to
terminal @ and terminal @.
@ Repeat the test in the order from step 5 to 1.
(3) The stepper motor is functioning properly if vibration is felt
7FUOOl I each time.
CLEANING THROTTLE BODY PARTS N14SlAA
(1) Clean all parts. A cleanser should not be used to clean the
following parts:
l Idle speed control servo
Immersing these parts in cleanser damages the insulation.

Wipe them with a cloth only.
(2) Check that the vacuum port and passage are not plugged
up. Clean the vacuum passage with compressed air.
INSPECTION AFTER REASSEMBLY

tDLE POSITION SWITCH CONTINUITY CHECK
(1) Check the continuity between connector terminal @ and
the body of the throttle position sensor both when the
throttle valve is at its completely closed position and at
maximum open position.
11
(2) If the results of the test do not conform to the above,

replace the idle position switch.
FUEL SYSTEM - Fuel Tank <WD> q?&g
FUEL TANK cFWD> NlMA-
,*. REMOVAL AND INSTALLATION

30-40 Nm
2-3 Nm 22-29 ft.lbs.
---15-20 Nm
11-14 ft.lbs.
15-22 ft.lbs.
Removal steps
l + 1. Return hose
l + 2. Vapor hose
3. Clamp
4. Fuel gauge unit connector
5. Electrical fuel pump connector
l + l q 6. High pressure fuel hose
l + 7. Filler hose
l + 8. Vapor hose
~~ 9. Self-locking nut
10. Tank band
11. Fuel tank
l + 12. Vapor hose
l + 13. Overfill limiter (Two-way valve)
I)+ 14. Fuel gauge unit
l + 15. Electrical fuel pump
16. Drain plug $TEeverse the removal procedures to reinstall,
17. Fuel tank cap (2) +e : Refer to “Service Points of Removal”:,,
18. Packing (3) *+ : Refer to “Service Points of lnstallatlon .
19. Fuel filler neck (4) m : Non-reusable parts
14-94 FUEL SYSTEM - Fuel Tank <FM/D>
SERVICE POINTS OF REMOVAL tilirro8AH
6. DISCONNECTION OF HIGH PRESSURE FUEL H;OSE

Caution
INSPECTION N14GCAl
l Check the hoses and the pipes for crack or damage.

l Check the fuel tank cap for malfunction.
l Check the fuel tank for deformation, corrosion or crack.
0,. Check the fuel tank for dust or foreign material.
NOTE
If the inside of the fuel tank is to be cleaned, use any one of
the following:
(1) Kerosene
(2) Trichloroethylene-
(3) A neutral emulsion type detergent
Outlet side _ Inlet side OVERFILL LIMITER (TWO-WAY VALVE)

Set a hand vacuum pump at inlet side or outlet side; the valve
is good if, when a negative pressure (vacuum) is applied, air
flows after a slight negative pressure is initially maintained. -
01 W838
SERVICE POINTS OF INSTALLATION. Nl4DDAL
15. INSTALLATION OF ELECTRICAL FUEL PUMP

(1) Align the three positioning projections of the packing
with the holes in the fuel pump.
(2) When the fuel pump is installed, the holding bolt at the
lower side of the fuel tank should be installed first.
Care should be taken at this time that the O-ring is not
pinched.
Positioning projection
14. INSTALLATION OF FUEL GAUGE UNIT

Align the two positioning projections of the packing with
the holes in the fuel gauge unit.
Caution
When mounting the fuel gauge unit, incline the float at 4
the end leftward, and insert it into the fuel tank. Since -,
the reserver cap is provided in the fuel tank, the fuel
gauge unit will contact the reserver cap if the fuel
gauge unit is inclined rightward during insertion.
03A0220
FUEL SYSTEM - Fuel Tank <MID>
13’. INSTALLATION OF OVERFILL LIMITER (TWO-WAY
VALVE)
Install so that the overfill limiter is facing in the direction
W304I I
12. CONNECTION OF VAPOR HOSE/l. RETURN HOSE

When attaching the fuel hose to the pipe, be sure that the
hose is attached as shown in the illustration.
Standard value: 25-30 mm (l&1.2 .. t@.).”
I 03FDO7 1
9. INSTALLATION OF SELF-LOCKING NUT

Tighten the self-locking nuts until the rear end of the tank
band contacts the body.
Tank band
03AO229
6. CONNECTION OF VAPOR HOSE/7. FILLER HOSE

(1) The vapor hose should be connected all the way at the
I I tank, and approximately 40 mm (1.6 in.) at the filler
\ \\u \ I \I-
neck.
(2) The end of the filler hose with the shorter straight pipe
part should be connected at the tank side.
03AO189
-.
?4 03FOO7 A
6. CONNECTION OF HIGH PRESSURE FUEL HOSE TO
Flare nut FUEL PUMP
Temporarily tighten the flare nut by hand, and then tighten ;Jt
it to the specified torque, being careful that the high ’
pressure fuel hose does not become twisted.
Caution
When tightening flare nut, be careful not to bend or
twist line to prevent damage to fuel pump low
connection.
Se&e s i d e 03~043
2. CONNECTION OF VAPOR HOSE/l. RETURN HOSE

When attaching the fuel hose to the pipe, be sure that the
hose is attached as shown in the illustration.
Standard value: 25-30 mm (1 .O-1.2 in.)
03FOO7
FUEL SYSTEM - Fuel Tank <AWD>
FUEL TANK <AWD> N140A-A
i. REMOVAL AND INSTALLATION

eDraining of the fuel. *Measurement of Fuel Pressure
@Release of Residual Pressure from High (Refer to P.14-44, 52.)
Pressure Fuel Hose l .Supplving of the Fuel.
(Refer to P.14-44.)
1-2 Nm 8
25-35 Nm
‘*-*: ft-‘bs*
9-14 Nm
- 7-10 ft.lbs.
- 9
- 7
03AO262
15-20 Nm
11-14 ftlbs.
Removal steps l 4 12. Hole cover

1. Fuel tankcap 14. Fuel tank
2. Packing 15. Overfill limiter (Two-way valve)
3. Drain plug l + 16. Fuel pump and fuel gauge unit assembly
4. Return hose 17. Fuel filler neck
5. Vapor hose
_- 4* 6. High pressure fuel hose
7. Fuel filler hose
8. Cable band FyTEeverse the removal procedures to reinstall.
9. Protector (2) ~~ : Refer to “Service Points of RemoveI”.
10. Vapor pipe (3) l + : Refer to “Service Points of Installation”.
11. Vapor hose (4) m : Non-reusable parts
14-98 FUEL SYSTEM - Fuel Tank <AWD>
SERVICE POINTS OF REMOVAL N14G6AHl
6. DISCONNECTION OF HIGH PRESSURE FUEL HGSE

Caution
INSPECTION N14GCAH
l Check the hoses and the pipes for crack or damage.

l Check the fuel tank cap for malfunction.
l Check the fuel tank for deformation, corrosion or crack.
l Check the fuel tank for dust or foreign material.
NOTE
If the inside of the fuel tank is to be cleaned, use any one of
the following:
(1) Kerosene
(2) Trichloroethylene
(3) A neutral emulsion type detergent
OVERFILL LIMITER (TWO-WAY VALVE)
Set a hand vacuum pump at inlet side or outlet side; the valve
is good if, when a negative pressure (vacuum) is applied, air
flows after a slight negative pressure is initially maintained.
01 W636
SERVICE POINTS OF INSTALLATION N14GDAO
16. INSTALLATION OF FUEL PUMP AND FUEL GAUGE

UNIT ASSEMBLY
Align the three positioning projections of the packing with
the holes in the fuel pump and fuel gauge unit assembly.
Positioning projection 03AO257
12. INSTALLATION OF HOLE COVER

) Before installing the hole cover, apply the specified
sealant to the rear floor pan.
Specified sealant: MOPAR Rope Caulk Sealer 3116
x 80” roll Part No.4026044 or
equivalent
!) After installing the fuel pump and fuel gauge assembly,
start the engine and check to ensure that there is no
fuel leakage.
\ 03A0256
p&&g
FUEL SYSTEM - Fuel Pump, Fuel Gauge Unit and Overfill Limiter (Two-Way Valve) <FWD>
FUEL PUMP, FUEL GAUGE UNIT AND OVERFILL LIMITER (TWO-WAY

J-. VALVE) <FWD>
REMOVAL AND INSTALLATION NWJA-
eDraining of the Fuel
l supplying of the Fuel
1.4-2.2 ft.lbs.
/ 1.4-2.2 ft.lbs.
21-31 Nm
80-100 Nm+
6.5- 10 ftlbs.
13AO333
Qel pump removal steps Overfill limiter removal steps

l * 1. Connection for fuel pump connector 11. Connection for vapor hose
C+ ~~ 2. High pressure fuel hose l 12. Overfill limiter (Two-way valve)
C+ l + 3. Self lockingnut
4. Lateral Pod attaching bolt
a* 5. Lateral rod and body connection
l I 6. Bolt
l + 7. O-ring
l 8. Electric fuel pump
Fuel gauge unit removal steps FF:everse the removal procedures to reinstall.
W e+ 3. Self locking nut (2) +e : Refer to “Service Points of Removal”.
4. Lateral rod attaching bolt (4) m : Non-reusable parts
c* 5. Lateral rod and body connection (5) For places indicated by the * symbol, first tighten
9. Connection for fuel gauge unit connector loosely, and then, with the vehicle unladen, tighten
I)+ 10. Fuel gauge unit completely.
14-100 FUEL SYSTEM - Fuel Pump, Fuel Gauge Unit and Overfill Limiter (Two-Way Valve) 4WD>
SERVICE POINTS OF REMOVAL NI4tmM

Refer to P.14-94.
3. LOOSENING OF SELF-LOCKING NUT

Loosen the self-locking nuts to the end of the stud bolt.
5. DISCONNECTION OF LATERAL ROD AND BODY
Disconnect the lateral rod right side body coupling; then
lower the lateral rod and use wire or similar material to
suspend from the axle beam.
INSPECTION N14UcM

Refer to P.14-94.
SERVICE POINTS OF INSTALLATION N14UDAA
12. INSTALLATION OF OVERFILL LIMITER (TWO-WAY

VALVE)
Refer to P.14-95.
10. INSTALLATION OF FUEL GAUGE UNIT
Refer to P.14-94.
8. INSTALLATION OF ELECTRIC FUEL PUMP/ 7. O-RING /
6. BOLT
Refer to P.14-94.
3. TIGHTENING OF SELF-LOCK NUT
Refer to P.14-95.
2. CONNECTION OF HIGH PRESSURE FUEL HOSE
Refer to P.14-96.
1. CONNECTION OF FUEL PUMP CONNECTOR
After connecting the fuel pump connector, check the fuel
pressure. (Refer to P.1444, 52.)
FUEL SYSTEM - Fuel Pump, Fuel Gauge Unit and Overfill Limiter (Two-Way Valve) <AWD>
FUEL PUMP, FUEL GAUGE UNIT AND OVERFILL LIMITER (TWO-WAY

_ VALVE) <AWD> - “:“-
: _..
REMOVAL AND INSTALLATION N14UA-A’
*Draining of the Fuel.
asupplying of the Fuel. 1-2 Nm
0.7-1.4 ft.lbs.
03A0263
Removal steps
1. Fuel pump and fuel gauge unit assembly
connector
I)4 2. Hole cover
3. Overfill limiter (Two-way valve) FyEeverse the removal procedures to reinstall.
4* 4. High pressure fuel hose connection (2) l * : Refer to “Service Points of Removql”.
l + 5. Fuel pump and fuel gauge unit assembly (3) l + : Refer to “Service Points of Installation”.
SERVICE POVNTS OF REMOVAL N14UBAAI

., I’
Refer to P.14-98.
3
INSPECTION N~4UCAAl

Refer to P.14-98.
“,, 2
SERVICE POINTS OF INSTALLATION N14UDAAa
5. INSTALLATION OF FUEL PUMP AND FUEL GAU6E

UNIT ASSEMBLY 1,
Refer to P.14-98.
-2. INSTALLATION OF HOLE COVER
Refer to P.14-98.
14-102 FUEL SYSTEM - Fuel Line and Vapor Line
FUEL LINE AND VAPOR LINE

REMOVAL AND INSTALLATION NuKn-
rPre-removal Operation
l Removal of the Batten/ Trav
(Refer to GROUP 8-Starter Motor)
ORelease of Residual Pressure from High
1
*Measurement of Fuel Pressure (Refer to
P.1444, 52.)
l lnstallatron of the Battery Tray
Pressure Hose. (Refer to GROUP 8-Starter Motor)
(Refer to P.14-44.)
4 - 6 Nm 25-35 Nm 9-14 Nm 30-40 Nm

3 - 4 ft.lbs. 16-25 ftlbs. 7-10 ft.lbs. 22-29 ft.lbs.
9 - 1 4 Nm
7-10 ftlbs.
I
9-14 Nm
9-14 Nm 9-h Nm 9-i4 Nm

7-10 ft.lbs. 7-10 ft.lbs. 7-10 ft.lbs.
7-
9 - 1 4 Nm
7- 10 ft.lbs.
25-35 Nm
7-10 ftlbs. 16-25 ft.lbs.
<AWD>
7-10 ft.lbs. 7-10 ft.lbs.

7- 10 ft.lbs.
Removal steps
l * 1. Eye bolt
l + 2. High pressure fuel hose
+e l + 3. Fuel filter
I)+ 4. Fuel return hose
5. Check valve
6. Clamp
~~ 7. Fuel vapor hose
8. Vapor pipe assembly
9. Canister
10. Canister holder NOTE
l * l * 11. Clamp (I) Reverse the removal procedures to reinstall.
12. Fuel main pipe (2) +e : Refer to “Service Points of Removal”.
13. Fuel return pipe (3) l * : Refer to “Service Points of Installation”.
14. Fuel vapor pipe (4) m : Non-reusable parts
FUEL SYSTEM - Fuel Line pnd Vapoi- @f&
SERVICE. POINTS OF REMOVAL N14KSAl.a
1. REMOVAL OF EYE BOLT

Remove the eye bolt while holding the’ fuel filter nut
securely.
Caution.
Cover the hose connection with ragS: to prevent splash
of fuel that could be caked by some residual pressure
3. REMOVAL OF FUEL FILTER

Mounting (1) Loosen the main pipe blare nut-while holding the fuel
bolts
filter nut securely.
(2) Remove the fuel filter mounting bolts, and then remove
the fuel filter from the bracket.
!
11. REMOVAL OF CLAMP
After removing the crossmember, remove the clamp.
(Refer to GROUP 2-Centermember and Crossme ber.)
T
pipe ,.
L
INSPECTION Ni&CAB
l Check the hose and pipes for cracks, bend, d,eforrnatiorr

and clogging.
l Check the canister for clogging. 1
l Check the fuel filter for clogging and damage.

~a
Nl4KDAl
11. INSTALLATION OF CLIP

(1) Insert the clip.
(2) Insert the crossmember. (Refer to GROUP 2-Center-
member and Crossmember.) ,. ,,$l
7. INSTALLATION OF FUEL VAPOR HOSE/4. FUEL RE-

TURN HOSE
(1) If the fuel pipe has a stepped part, connect the fuel
03FOOO
hose to the pipe securely, up to the stepped part, as
-. shown in the figure.
(2) If the fuel pipe does not have a stepped part, connect
the fuel hose to the pipe securely, so that it is the
standard value.
Standard value: 20-25 mm (.&I.0 in.)
!- 03FOO7 [
FUEL SYSTEM - Fuel Line and VaDor Line/Fuel Filter
3. INSTALLATION OF FUEL FILTER
f+-----Eye bolt
High-pressur (1) When installing the fuel filter, first temporarily install the
hose Gasket filter to the filter bracket; then insert the main pipe at ‘*
the connector part of the filter, and manually screw in ..
Fuel filter the main pipe’s flare nut.
(2) Holding the fuel filter nut, tighten the fuel main pipe’s
Flare nut flare nut and eye bolt at the specified torque. Then
tighten the filter to the bracket.
Fuel main
pipe
2. INSTALLATION OF HIGH PRESSURE FUEL HOSE

Apply engine oil to the hose union.
Insert the hose, being careful not to damage the O-ring, and
tighten securely.
Caution
Because there is high pressure applied between the
fuel pump and the injection mixer, be especially sure
\- Apply engine that there is no fuel leakage in this area.
&ring Oi’
FUEL FILTER
REMOVAL AND INSTALLATION N14VA-

@Release of Residual Pressure from High 18-25 ft.lbs.
Pressure Hose.
(Refer to P.14-44.) 7’
I I
1
vd-
Fuel filter removal steps

** 1. Eye bolt
2. Gasket
3. Connection for Fuel high-pressure hose
4. Gasket
5. Connection for Fuel main pipe
6. Mounting bolt
+e l 4 7. Fuel filter
NOTE
(1) Reverse the removal procedures to reinstall. Y
03A0231
SERVICE POINTS OF REMOVAL NlIVBAA
1. REMOVAL OF EYE BOLT

Refer to P.14-103.
7. REMOVAL OF FUEL FILTER
Refer to P.14-103.
SERVICE POINTS OF INSTALLATION N14VCAA
7. INSTALLATION OF FUEL FILTER

Refer to P. 14-104.
ENGINE CONTROL - SpecificatiodTroubleshooting
ENGINE CONTROL
-.
SPECIFICATIONS
SERVICE SPECIFICATIONS N14CEA
Standard value
Accelerator cable play mm (in.)
<M/T> 1-2 (.04-.08)
dfi> 3-5 (.12-.20)
Accelerator switch switching point mm (in.) 2-6 (.08-.24)
TORQUE SPECIFICATIONS N14CkA

I
Items Nm ft.lbs.
Accelerator arm bracket to body 8-12 6-9

Throttle body side inner cable to air intake plenum 4-6 3-4
Accelerator arm side inner cable to body 4-6 3-4
: j,
_- LUBRICANTS
Accelerator arm and return spring MOPAR Multi-mileage Lubricant Part No.2525035 As required
or equivalent
SEALANT N14CE.-B
I--
Accelerator arm bracket ~ I 3M ATD Part No.8663 or equivalent I
TROUBLESHOOTING N14EGABa
ACCELERATOR CABLE AND ACCELERATOR PEDAL

Throttle valve will not Misadjusted accelerator cable

fully open or close Adjust
Misadjusted automatic speed-control cable
Broken return spring

Replace
-. Throttle lever malfunction
Accelerator pedal Accelerator pedal wrongly tightened

operation not smooth Repair
Misinstalled accelerator cable
(over acceleration)
Accelerator cable requires lubrication Lubricate or replace
14-106 ENGINE CONTROL - Service Adjustment Procedures
SERVICE ADJUSTMENT PROCEDM%,&

A C C E L E R A T O R C A B L E CNSPECTION AN&I ”
ADJUSTMENT
For models equipped with the auto-cruise control systemrefer
to P.14-136.
(1) Turn air conditioner and lights OFF.
Inspect and adjust at no load.
2) Warm engine until stabilized at idle.
3) Confirm idle speed is at prescribed rpm.
4) Stop engine (ignition switch OFF).
5) Confirm there are no sharp bends in accelerator cable.
6) Check inner cable for correct slack.
7) If there is too much slack or no slack, adjust play by the
TAir intake Adjusting bolts following procedures.
@ On models with an SOHC engine, turn the ignition
switch to the ON position (without starting the engine)
and leave in that condition for approximately 15
seconds.
@ Loosen the adjusting bolts on the air intake plenum, and

then secure the outer cable so that the free play of the
inner cable will be the standard value.
Standard value: jlr
<M/T> l-2 m m (.04-.08 in.) \. *
<A/T> 3-5 m m (.12-.20 in.)
NOTE
If there is excessive play of the accelerator cable, the
vehicle speed drop (“undershoot”) when climbing a slope
Idle switch 03A,,2.8 will be large.
If there is no play (excessive tension) of the accelerator
cable, the idling speed will increase.
(8) After adjusting, confirm that throttle valve fully opens and
closes by operating pedal.
(9) Adjust accelerator cable play and confirm throttle lever
stopper touches the idle switch.
ACCELERATOR SWITCH INSPECTION AND

ADJUSTMENT NlWlEB
(1) After warming up the engine, check to be sure that the

accelerator switch is ON when the accelerator pedal’ is in
the free condition. If there is a malfunction, adjust by using
the adjusting bolt.
I (2) Press the accelerator pedal by hand until the accelerator
switch switches from ON to OFF and confirm that the
amount of pedal movement (A in the figure) is within the
standard value range.
Standard value:
Accelerator switch switching point
2-6 mm (.08-.24 ‘in.)
(3) If the distance (A in the figure) is not within the standard
value, adjust it by using the adjusting bolt.
07RQ024
L
ENGINE CONTROL - Engine Contrd
ENGINE CONTROL
Y
REMOVAL AND INSTALLATION N14QA-
1 *Accelerator Cable Adjustment (Refer to

*Accelerator Switch Adjustment (Refer to
Es.-
i - 7 I
I
Q 7
_-
07AOO25
Removal steps \
5
1. Adjusting bolt
2. Throttle body side inr er cable 6
l 3. Bushing
+4 4. Accelerator arm side inrler cable
4* 5. Accelerator pedal
6. Spring
7. Accelerator switch CI nrnectar <AiT>
l + 8. Accelerator arm brat e t
9. Split pin
l + 10. Accelerator arm NOTE
I)+ 11. Return spring (I) Reverse the removal procedures to reinstall.
12. Accelerator switch < A/T> (2) ++ : Refer to “Service Points of Removal”.
13. Accelerator arm stop w r (3) l : Refer to “Service Points of Installation”.
14. Bolt <A/T> (4) m : Non-reusable parts
1
SERVICE POINTS OF REMOVAL NlUlBAC
5. REMOVAL OF ACCELERATOR PEDAL

Pull the left side of the accelerator pedal toward you, and
then remove the accelerator pedal from the accelerator
arm.
14-108 ENGINE CONTROL - Engine Control
INSPECTION j N%PJCf@
l Check the inner and outer cable for damage. $+
l Check the cable for smooth movement.
--
l Check the accelerator arm for bending.
l Check the return spring for deterioration.
l Check the connection of bushing to end metal fitting.
l Check the accelerator switch for ON/OFF switching.
SERVICE POINTS OF INSTALLATION N14DDAP
ll.APPLlCATlON OF GREASE TO RETURN SPRING/

10. ACCELERATOR ARM
Apply multipurpose grease around the each moving point
of the accelerator arm.
8. APPLICATION OF SEALANT TO ACCELERATOR ARM

BRACKET
Apply the specified sealant to the bolt mounting hole, and
then tighten the accelerator arm bracket. ,%
Specified sealant: 3M ATD Part No.8663 or equivalent
4. APPLICATION OF GREASE TO ACCELERATOR ARM

SIDE INNER CABLE/B. BUSHING
(1) Securely install the resin bushing of the accelerator
cable on the end of the accelerator arm.
(2) Apply multipurpose grease around the cable end.
AUTO-CRUISE CONTROL SYSTEM - Snecifications 14-109
AUTO-CRUISE CONTROL SYSTEM
.-4.
SPECIFICATIONS
GENERAL SPECIFICATIONS NUCA-B
Auto-cruise control switch
Rated load A
MAIN 3.OkO.5
SET 0.2fO.l
RESUME 0.2kO.l
Voltage drop V 0.2 or less
Stop light switch

Rated load A 0.1-0.9
Voltage drop (at rated load) V 0.25 or less
Clutch switch
Rated load A 0.005-l
Voltage drop (at rated load) V 0.15 or less
Auto-cruise control unit

Range of speed control km/h (mph) 40 (25)_+3 (1.81-145 (90)_+5 (3.1)
Auto-cruise control actuator

Drive system Vacuum type
Stroke mm (in.) 38-42 (1.5-I .7)
Auto-cruise vacuum pump

Rated load A 0.4 or less
Accelerator cable play mm (in.)

<M/T> O-l (O-.04)
4l-b 2-3 (.08-,121
Throttle cable play mm (in.) 1-2 (.04-.08)
Auto-cruise cable play mm (in.) 1-2 (.04-.08)
Control valve, Release valve resistance Q 50-60
TORQUE SPECIFICATIONS N14CGC
Items Nm ftlbs.
Link protector 4-6 3-4
-. Link assembly 9-14 7-10
Auto-cruise vacuum pump 4-6 3-4
Accelerator cable plate 4-6 3-4
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting
TROUBLESHOOTING N14,EBPW
The auto-cruise control system performs control functions for
the setting or cancellation of the fixed-speed driving speed
based upon the data provided by input signals. As a result,
when the auto-cruise control system is canceled by abnormal
system operation, the cause of the cancellation is memorized
in a separate circuit by the ECU, thus providing the ECU with
the self-diagnosis function by certain fixed patterns, as well as
the function of being able to check whether or not the ECU’s
input switches or sensor are normal. Thus, by effectively using
these function, the time required checking and repair can be
shortened.
TROUBLESHOOTING QUICK-REFERENCE CHART

Auto-cruise control system is canceled
when cancellation not wanted.
ECU: Electronic control unit
Or, the auto-cruise control system cannot
be set after an automatic cancellation.
+-
Can the auto-cruise control system be set No c Check the diagnosis code
now? (Refer to P.14-122.)
I I
Yes
Yes Check the diagnosis code

Did the problem reoccur? __c (Refer to P.14-122.)
No (new normal) l Check whether or not, then, the vehicle was driven on a steep
slope.
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 144w
NOTE
Auto-cruise control system cannot be set. This chart is to be used, then, for troubleshooting if it is not
possible to use the self-diagnosis for checking.
Prepare to conduct input check.
()
(Refer to P.14lr
Where codes No.21, 22, 23, 25 and 26 No

disolaved when, with the vehicle stationary, -8
‘#
the’ input check codes were recalled?
c L--y--
-
Arc 3 tt ie results of all inout checks normals?
Check results Probable cause Remedy

ii”,:” chart
Code 21 remains even though SET SET switch ON mal- Replace the control No.2
switch is set to OFF. function switch
SET switch input line Repair the harness

short-circuit
Code 22 remains even though RE- RESUME switch ON Replace the control No.3
:- SUME switch is set to OFF. malfunction switch
RESUME switch input Repair the harness
line short-circuit
Code 23 is not canceled even if the Malfunction of stop Replace stop light No.6
stop light switch is turned OFF by light switch circuit. switch or repair har-
releasing the brake pedal. ness.
Code 25 does not disappear, and Malfunction of the Check or repair the No.4
code 24 does not appear, even vehicle-speed sensor vehicle speed sensor
though vehicle speed reaches appro- circuit (damaged or dis- circuit.
ximately 40 km/h (25 mph) or higher. connected wiring, or
short-circuit)
Code 26 is not canceled even if the Malfunction of clutch Replace clutch switch No.8
clutch switch is turned OFF by re- switch circuit. or repair harness.
leasing the clutch pedal.
Code 26 is not canceled even if the Malfunction of inhibitor Replace inhibitor switch No. 7
select lever is moved to anything but switch circuit. or repair harness.
N, P <AI-T>.
the auto-cruise vacuum pump circuit. NOTE _. . . e_,

1 (Go to check chart No.5.) I If the results of the check oT tne auro-crutse vacuum pump
circuit (check chart No. 5) and of the auto-cruise vacuum pump
and actuator itself (P.14-138.) reveal no abnormal condition,
replace the electronic control unit (ECU).
-.
14-112 AUTO-CRUISE CONTROL SYSTEM - Troubleshootina
Trouble symptom Probable cause Check chart No. Remedy
l The set vehicle speed varies Malfunction of the vehi- No.4 Repair the vehicle speec
greatly upward or downward. cle speed sensor circuit sensor system, or re-
l “Hunching” (repeated alternating place the part.
acceleration and deceleration) Malfunction of the
occurs after setting is made. speedometer cable or
speedometer drive gear
Auto-cruise vacuum No.5 Repair the auto-cruise
pump circuit poor con- vacuum pump, or
tact replace the part.
Malfunction of the auto-

cruise vacuum pump
Malfunction of the ECU - Replace the ECU.
The auto-cruise control system is not Damaged or discon- If the input check code Repair the harness or
canceled when the brake pedal is netted wiring of the No. 23 indicates a mal- replace the stop light
depressed. stop light switch input function. No. 6 switch.
circuit; brake switch (for
auto-cruise control) mal-
function (short-circuit)
Auto-cruise vacuum No. 5 Repair the harness or

pump drive circuit short- replace the auto-cruise
circuit vacuum pump.
The auto-cruise control system is not Damaged or discon- If the input check code Repair the harness, or
canceled when the clutch pedal is netted wiring of clutch No. 26 indicates a mal- repair or replace the
depressed. (vehicles with a manual switch input circuit function. No. 8 clutch switch.
transaxle)
(It is canceled, however, when the Clutch switch improper
brake pedal is depressed.) installation (won’t
switch ON)
The auto-cruise control system is not Damaged or discon- If the input check code Repair the harness, or
canceled when the shift lever is netted wiring of inhibi- No. 26 indicates a mal- repair or replace the in-
moved to the “N” position. (vehicles tor switch input circuit function. No.7 hibitor switch.
llvith an automatic transaxle)
[It is canceled, however, when the Improper adjustment of
Drake pedal is depressed.) inhibitor switch
Cannot decelerate by using the SET Temporary damaged or No. 2 Repair the harness or
switch disconnected wiring of replace the SET switch.
SET switch input circuit
Auto-cruise vacuum No.5 Repair the harness or
pump circuit poor con- replace the auto-cruise
tact vacuum pump and
actuator.
cruise vacuum pump
and actuator (including
clogging of negative
pressure passage)
AUTO-CRUISE CONTROL SYSTEM - Tr6ubleshootina
,;+ >,, a”:;-c li: i:
Trouble symptom Probable cause Check chart No. Remedy .’ ’
9 . /~ A%
.z .
Cannot accelerate or resume speed Damaged or discon- No.3 Repair the harness‘&
by using the RESUME switch. netted wiring, or short- replace the RESUME
circuit, of RESUME switch.
switch input circuit
Auto-cruise vacuum No. 5 Repair the harness or

pump circuit poor con- replace the auto-cruise
tact vacuum,pump and
actuator.
cruise vacuum pump
and actuator (including
air leak from negative
pressure passage)
Malfunction of the ECU - . Replace the ECU.
Auto-cruise control system can be Malfunction of the No.4 Repair the vehicle-
set while traveling at a vehicle speed vehicle-speed sensor speed sensor system,
of less than 40 km/h (25 mph), or circuit or replace the part.
there is no automatic cancellation at
that speed. Malfunction of the ‘I,
speedometer cable or
the speedometer drive 6i
gear
The indicator light of combination Damaged or discon- - Repair the harness or

meter does not illuminate. netted bulb of indicator replace the bulb.
(But auto-cruise control system is light
c-
normal.)
Harness damaged or
disconnected ‘._,.
Malfunction of control function by Malfunction of circuit re- No. 9 Repair the harness or
ON/OFF switching of ELC 4 A/T lated to accelerator replace the part.
accelerator switch switch OFF function
,Non-operation of damper clutch,
2nd gear hold, etc.) Malfunction of the ECU
3verdrive is not canceled during Malfunction of circuit re- No. 10 Repair the harness or
‘ixed speed driving. <AA> lated to overdrive can- replace the part.
cellation, or malfunction
10 shift to overdrive during manual of ECU
driving. <A/T>
14-114 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting
CHECK CHART
1I. CHECKING THE CONTROL UNIT POWER SUPPLY CIRCUIT
Ignition Description of operation
switch When the cruise control switch (CRUISE) is switched ON while
<IG,> the ignition switch is ON, current flows to the ignition switch
I
(IG,), to fuse No.(ll) of the junction block, and to the
I
A F” cruise-control switch (MAIN switch), the control unit, and to
7 ground.
Junction 8 When the ignition switch is turned OFF, the MAIN switch in the
block cruise control switch is also turned OFF.
3
I
t
Troubleshooting hint
Crurse-
control ECU terminal voltage
switch
OFF Terminal Signal Conditions Terminal
No. voltage
t 2 Control unit When the cruise- System
power supply control switch voltage
(CRUISE) is
switched ON.
8, 14 Control unit At all times ov
ground
NOTE
+: The connector Nos. in Section “AUTO-CRUISE CONTROL
RELATED HARNESSES” and the connector names in the
junction block are represented.
(Applicable on the next page and subsequence.)
13AO363
2. CHECKING THE SET SWITCH

Description of operation
When the SET switch is switched ON (at the vehicle speed
desired to be maintained, and with the CRUISE switch of the
cruise-control switches ON) that vehicle speed is maintained as
a constanf speed.
Auto-cruise Furthermore, the constant speed is gradually reduced (the
control unit “coasting” feature) when the SET switch is pressed and held
while the vehicle is traveling at the previously set constant
speed, and, when the SET switch is released, the vehicle then
maintains that newly set constant speed (the speed at which
the SET switch was released).
Current flows to the control unit, the cruise control switch
(“SET”), and to ground.
Diagnosis-No. 15 (automatically cancelled)
ECU terminal voltage
1 Terrrnal 1 S i g n a l 1 ConditionsrEl
13AO364
3. CHECKING THE RESUME SWITCH CIRCUIT . ” , . .
The set speed (before cancellation) resumes when the RE-
SUME switch is switched ON, even if the constant-speed
control has been cancelled.
That speed will not resume, however, even if the RESUME
Auto-cruise switch is switched ON, if the CRUISE switch is switched OFF
control unit and if the vehicle speed decreases to 40 km/h’ (25 mph) or
lower.
In addition, when the RESUME is switched ON and held while
the vehicle is traveling at a constant speed, the vehicle speed
will increase; the speed at which the switch is subsequently
released will become the newly set constant speed.
Current flows to the control unit, the cruise control switch
(RESUME), and to ground.
Cruise-control
switch Troubleshopting hint
Diagnosis-No. 15 (automatica& canceelied)
Signal Conditions Terminal

Tez3!al voltage
18 RESUME When the RESUME OV
switch switch is,switched
ON.
When the RESUME ;;;;g;
“o”;:“h IS swrtched
\ ‘)
13AO365 ,,
4. CHECKING THE VEHICLE-SPEED SENSOR CIRCUIT

The vehicle-speed sensor is installed within the sljeedometer; it
sends to the control unit pulse signals that are proportional to
the rotation speed (i.e., the vehicle speed) of the transaxle’s
Auto-cruise output gear.
control unit This vehicle-speed sensor is the reed switch type of sensor; it
generates four pulse signals for each rotation of the speedo-
meter’s driven gear.
Combination Move the vehicle

meter forward slowly.
Junction
block
13A0366
5. CHECKING THE AUTO-CRUISE CONTROL VACUUM PUMP
Ignition Hold mode
switch (IG,) When the SET switch is turned ON by the driver turning the
I CRUISE switch ON when a determined speed is reached, the
control unit receives a set signal, and turns the auto-cruise
vacuum pump motor ON. After the constant speed is reached,
the motor, control valve and release valve are repeatedly turned
ON and OFF according to driving conditions.
Acceleration mode
When the RESUME switch is pressed, the control unit receives
Cruise- a RESUME signal and it not only turns the auto-cruise vacuum
control
switch pump motor ON but also turns the control valve and release
SET
valve ON (valve is closed).
ON Deceleration mode
When the SET switch is held down, the control unit receives a
set signal and it not only turns the auto-cruise vacuum pump
motor and control valve OFF (valve is opened) but also turns the
release valve ON (valve is closed).
Release mode
When the CRUISE switch is turned OFF, the control unit
receives a cancel signal and it not only turns the auto-cruise
vacuum pump motor OFF but also turns the control valve and
release valve OFF (valve is opened).
AUTO-CRUISE CONTROL SYSTEM - Troubltyshootf$
6. CHECKING THE STOP LIGHT SWITCH CIRCUIT
When the brake pedal is depressed during constant-speed
travel, the stop light switch’s (NC) contacts for the cruise-
Sub fusible link @ control system open, with the result that the current to the
auto-cruise vacuum pump is interrupted, thus canceling the
constant-speed travel.
At the same time, moreover, the closing of the (NO) contacts
for the stop light results in the sending of the cancel signal to
the control unit, so that the auto-cruise vacuum pump current is
discontinued within the control unit, thereby canceling the
constant-speed travel.
The flow of current is from the sub fusible link @I to fuse No. @
of the junction block, the stop light switch, and the control unit.
Terminal Signal
No.
15 Stop light
vacuum switch (load pedal is depressed.
w-v side)
Stop light
t-i-
Auto-cruise
i-._ control unit
NOTE
NC: Indicates ON at all times. (For cruise contra!)
NO: Indicates OFF at all times. (For stop light) l,_
13A0366
7. CHECKING THE INHIBITOR SWITCH CIRCUIT <A/T>
Auto- Description of operation

cruise
control The inhibitor switch also functions as the switch for the starter.
unit If the selector lever is moved to the “N” position during
constant-speed travel, current flows to the control unit, inhibitor
Vehicles with x Vehicles without switch, theft-alarm starter relay (vehicles with theft-alarm
theft-alarm 5 I theft-alarm system system), starter motor, and to ground; the cancel signal is
s y s t e mr b therefore input to the control unit, thus canceling the constant-
speed travel. 5
*Theft- ’,I._nI I
alarm z Troubleshooting hint
starter OF: N A
relay Ql _3 ECU terminal voltage

TeE!al voltage
1 Inhibitor switch At all times System
voltage
Inhibitor
switch
NOTE starter
C.
Refer to GROUP 8- motor

Theft-alarm System for
the + (asterisk) on
“Theft-alarm System”. 13A036B
8. CHECKING THE CLUTCH SWITCH CIRCUIT <M/T>
If the clutch pedal is pressed wht driving at a constant speed,
the clutch switch is turned ON and a cancel signal is input to the
control unit and the determined driving speed is canceled
Auto-cruise because current flows to the clutch, switch junction block from
control the control unit and to ground.
unit
9
t--l--
Terminal Signal Conditions Terminal
2 No. voltage
Clutch
switch 1 Clutch switch When the clutch
OFF ON pedal is depressed.
1
m
When the clutch
11
pedal is not de-
Junction I pressed.
I
block I
13AO370
9. CHECKING THE CIRCUITS RELATED TO THE ACCELERATOR SWITCH OFF FUNCTION

<A/T>
Ignition switch
<IG2> Description of operation
m The accelerator switch is a switch that detects the operational
status of the accelerator pedal; it is one of the sensors of the
automatic, transaxle.
Because the status of the accelerator pedal during constant-
speed driving is non-operational, the ground circuit (transistor
Tr2) of the accelerator switch is switched OFF only during
constant-speed driving in order not to interfere wtth the function
of the automatic transaxle.
Terminal Signal Conditions Terminal
No. voltaoe
’ 3 Control unit At all times
power supply
9 Accelerator When the accel- ov
switch erator pedal is
& Accel- / depressed.
When the accel- System
erator pedal is not voltage
depressed.
\lOTE
JC: Indicates ON at all time.
13AO371 1 Not in operation ) OFF 1 ON (

1~~ppGJ”
10. CHECKING THE CIRCUITS RELATED TO THE OVERDRIVE-CANCELLATION FUNCTION <AiT>

switch This is a function that cancels the overdrive fur&on for a
certain fixed period of time, if .during constant-speed travel in
overdrive, the actual vehicle speed decreases to less than the
vehicle speed retained in the memory, and then after a short
time causes the vehicle speed to return to the vehicle speed
block retained in the memory.
Overdrive is cancelled under the following conditions.
If, during constant-speed travel, the actual vehicle speed
Ov&rive decreases to 7 km/h (4.4 mph) or more below the set vehicle
(16) speed.
Under either of the conditions described above, the overdrive-
ON signals output from the microcomputer (with the control
unit) are no longer output, and transistor Tr, is switched OFF.
As a result, transistor Tr2 is also switched OFF, causing the
Auto-cruise current passing through the overdrive switch of the selector
control unit handle to be interrupted at transistor Tr2, with the result that the
drive is controlled ‘at 3rd gear.

rerNmdra’ i voltage
10 4A/T control, When the overdrive $ta;;
unit ‘sw$ch IS swrtched
11 ;;tt;ive When the overdrive %‘Gg;

s&itch IS switched
A57
4Al-r (18)
control
unit
m
11. CHECKING THE THROTTLE POSITION SENSOR AND IDLE SWITCH CIRCUIT
<1.8L Engine> Description of operation “s
The throttle position sensor and idle switch are mounted in the ,
motor position sensor or throttle body and are sensors in the
MPI system. The idle switch is turned OFF when the accelera-
tor pedal is pressed and ON when it is released. In addition,
throttle position sensor output voltage varies according to the
degree of opening of the throttle valve.
Throttle <Throttle position sensor>
position
sensor Diagnosis-No. 17
<Idle switch>
Diagnosis-No. 17

TeKlna’ voltage
MPI control 4 Idle switch When accelerator
unit pedal is pressed XFgr
nw374
When accelerator ov
<2.0L DOHC Engine> pedal is released
ruise 5 Throttle When accelerator 4.OV-5.5V
I unit position sensor pedal is pressed
all the way down
When accelerator 0.48-0.72V
pedal is released
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting '14421
SELF-DIAGNOSIS CHECK
Self-diagnosis checking is performed when there has been an
automatic cancellation, without cancel switch operati’on.
(1) The following method can be used for checking the
diagnosis. Note that the diagnosis check connector is
located under the driver’s side instrument panel.
Connect a voltmeter between the ground terminal and the
terminal for auto-cruise control of the diagnosis check
connector.
It is possible to discover which circuit is the cause of the
16A065i cancellation by verifying the indication shown by the
voltmeter with the display patterns shown on the next
page.
Auto-cruise (2) When the diagnosis code No. is displayed, inspect accord-
ing to the inspection chart No. related to each code No.
NOTE
Canceling the diagnosis codes
The diagnosis codes remain in memory until the battery is
turned off but they can be canceled in the following ways
without disconnecting the battery terminals.
1. By turning on the ignition switch
16LOOS 2. By turning the cruise switch ON while the SET switch is ON
and then, within 1 second, turning the RESUME switch
ON. (Put into condition for input check reception)
3. By turning ON set SET switch and stop light switch at the
same time and continuing the ON condition for 5 seconds
or more.
4. By checking that the diagnosis codes are canceled using a
voltmeter.
DIAGNOSIS DISPLAY PAlTERNS AND CODES
Code Display patterns (output codes) Probable cause Check chart No.
No. (Use with voltmeter)
11 Abnormal condition of auto-cruise No. 5
“,;1 fl 1 j-- vacuum pump drive system
12 Abnormal condition of vehicle-speed sig- No.4

nal system
15" 12v Control switch malfunction (when SET No.2, 3

and RESUME switches switched ON
ov simultaneously for more than 25 seconds)
16" Abnormal condition of auto-cruise No.6,7,8
I ‘,“,-I
c o nrt r o l u n i t
17 Abnormal condition of throttle position No. 11

sensor
,3*0356 Abnormal condition of idle switch
NOTE
1. Codes indicated by the * symbol are displayed, if the conditions are satisfied, even if the system is
normal. In either case, the system is normal if it can be reset. If there is an automatic cancellation not
intentionally made by the driver, however, excluding cancellations explicitly made by the cancel
procedure, there may be a temporary malfunction such as poor contact of a harness connector even
though the system can be reset, and for that reason it is necessary to check according to each
individual check chart that is applicable.
Display when vehicle speed is 2. Diagnosis codes are displayed when, after cancellation of
approximately 20 km/h (12 mph) less than the auto-cruise control system, the vehicle speed de-
or before the auto-cruise control system creases to less than approximately 20 km/h (12 mph), and
is set
are canceled by turning OFF the battery or canceling the
diagnosis codes. (Refer to P.14-121.)
After the diagnosis codes in the memory are erased, if
ON (12V)
(when the power supply of the electroinc control unit is
switched ON once again) the power supply of the
OFF (OV) electronic control unit is normal, the diagnosis output
code display will be as below, regardless of whether the
system condition is normal or not.
Continuous ON/OFF signals will be displayed at 0.5-second
intervals.
(Refer to the figure at the left.)
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 14:f*L3’.
a * :;i’ _
INPUT CHECK
Input checks should be made when the auto-cruise’.contr$
system. cannot be set and when it is necessary to check.
(when a malfunction related to the auto-cruise control system,
occurs) whether or not the input signals are no’rmal.
NOTE
1. If inspection of self-diagnosis is necessary, confirm diag-
nosis code first and conduct input check.’
2. Input check can be conducted by set operations.
Self-diagnosis terminal outputs display patterns.
3. Display codes are displayed only if the circuit is normal
according to the conditions shown in the table on the next
page.
(1) The voltmeter is set in the same way as for the self-
diagnosis check.
(2) Turn the ignition switch to ON and switch OFF the CRUISE
switch.
(3) With the SET switch in the ON position, turn the CRUISE
switch ON. Then, within 1 .O second, place the RESUME
switch in the ON position..
(4) Perform each input operation according to the input check
03A0258
table (on the next page) and read the codes.
(5) Switch the CRUISE switch OFF.
INPUT CHECK TABLE
Check Input operation iI!e Display patterns (output codes) Check results
No. (use with voltmeter)
1 SET switch ON 21 X:Gayitch circuit
2 RESUME switch ON 22 12v RESUME switch cir-

cuit normal
ov
3 Stop light switch ON (brake 23 ;;pl;yht switch

pedal depressed)
4 Driving at approximately to 40 24 When both No. 4

km/h (25 mph) or higher and No. 5 can be
co,nfirmed, vehicle-
. speed sensor circuit
5 Driving at less than approx- 25 12v normal.
imately 40 km/h (25 mph) or
stopped ov
6 1. Clutch switch ON (clutch 26 Clutch switch inhibi-
pedal depressed) <M/T> 12v tor switch normal
2. Inhibitor switch ON (shift
lever to “N” or “P” range) ov
-aIT>
7 Throttle position sensor output 28 Throttle position

voltage over 1.5V (when the sensor normal
accelerator pedal is pressed
more than half way)
? Idle switch OFF (accelerator 29 Idle switch normal

pedal depressed)
NOTE 3. When each input operation is performed and

1. Each code will be displayed in an order of the signals for the conditions are received by
priority beginning from No. 1. the computer, each output code will be
If there is no display, it is possible that repeatedly displayed in the sequence of
there is a malfunction of the ECU power- priority for as long as that signal continues.
supply circuit or the SET and/or RESUME 4. If, during the display of output codes, the
switch, so check according to check input operation is canceled (if, for example,
charts 1,2 and 3. the SET switch is set from ON to OFF), the
2. Continue each input operation until the code will be displayed for one cycle of the
output code is emitted. display, but will not be displayed during the
If no output codes are emitted for inputs next cycle.
even though the display pattern is repe- This makes it possible, therefore, to check
ated two or more times, there is a the OFF condition (existence of not of a
malfunction of the switch sensor. short-circuit of the input line or the switch).
AUTO-CRUISE CONTROL RELATED HARNESSES

<ENGINE COMPARTMENT> <DASH PANEL>
1 ? 3 10 11
,’ 112 I$ ii 15r
1. Idle switch <2.0L DOHC engine>

is i7 --
2OAO402
2. Motor position sensor (Idle switch) <l BL

engine’>
3. Auto-cruise control vacuum pump
5. Starter motor
Ground Point 6. Inhibitor switch <A/T>
7. Auto-cruise control unit
8. Junction block
9. Self-diagnosis connector
10. Clutch switch <M/T>
11. Stop light switch
12. Ignition switch
13. Column switch
14. Accelerator switch <A/T>
15. Power/Economy changeover switch <A/T>
16. Overdrive switch <AK>
17. MPI control unit
18. 4Aff control unit
NOTE
Refer to P.14-126 for details about the mounting positicjkof
Junction Block the auto-cruise control unit, etc.
Front side Rear side

,-To engine room
To instrument
No To body
connection ) wiring
harness
AUTO-CRUISE CONTROL COMPONENTS LOCATION
Name Symbol 1 Symbol
Accelerator pedal switch <A/T> K Idle switch I D
Auto-cruise control actuator C Inhibitor switch <A/T>
Auto-cruise control switch
I Auto-cruise
I Auto-cruise
control unit
control vacuum pump
I
H
E
B
ziz&Gy+
Motor position sensor (Idle switch)
I
I Auto-cruise indicator light I F Throttle position sensor
Clutch switch <M/T> M Vehicle speed sensor (Reed switch) I G
4 A/T control unit I
NOTE
The “Name” column is arranged in alphabetical order.
<Engine compartment> <Interior>
<1.8L engine>
Motor 1
position sensor
I .F”l.O, VUUW
Vehicle speed sensor WA0728

Auto-cruise indicator light (Reed switch)
l /4’NTj$trol unit-
--
AUTO-CRUISE CONTROL CIRCUIT

<M/T> IGNITION
SWITCHtlGl)
1 AUTO-CRUISE
CONTROL UNIT
c-01
GND r GND $
V v v I
3 11 "'I 19 5v
G
z5 iz
m id s? I
SELF-DIAGNOSIS
CONNECTOR -1 E
- IF4
C-30FRONT SIDE I I
p&igq L
REVERSE SIDE
pl$Lzq
m m m
m
pzr$iiq m
,2-B
r
J/B47
c-55
‘--ya’
11 10 c-45
pliq
X35-AC-Ul516-NC
AUTO-CRUISE CONTROL SYSTEM - Trdubleshooting
IGNITION SIBLE
SWITCH(lG1)
I
1 c-47 ~ ‘
J/B J/B
yl8 y17
3 c-55
C”
COLUMN SWITCH
AUTO-CRUISE
CONTROL
0.85-GW
0 OPEN
0.85-G
2 EEECToR
16
AUTO-CRUISE c-01
CONTROL UNIT
AUTO-CRUISE
CONTROL-UNIT c-01
1 I_-_-_-_-_-_-__
I I - - - - - - - - - l
I
i
5
I I
8 t r!
t
--------------------- II II 2__------ 14 C-67
C-67
s 5 c!
%I c!Y i
e c!
rHROTTLE MOTOR
;gj&ON ;iW'O;;ON
t
3-02 B-03
1 IDLE
1 1 SWITCH
E-05
19
!4
rL
%
iV
MPI C-66
CONTROL
UNIT
KXW-AC-UllllM-NC
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 14L’1.31”
-=cA/T>
SUB SIBLE IGNITI IN IGNITION :ON
LIN 4 SWITCI ST)
-1
SWITCH(IG2) I(IG1) ,
!z ra
1
II3
A
c-47
1
J/B 1 J/B
0
10A
10A
c
C-52 3 c-50 6 c-45
c (liIals14r51sl]
3
7Flimsq’
c
3 z
14
LW$NATION
h'HEN 9 D-05
{EY IS I, 1(2~3~41516~715
, “‘I
?EMOVED WITH #gpT 01
‘7 lo~llll~l3ll4pm7
c iEK;Si- ALARM
SYSTEM I SYSTEM ,
2I I
u-zn
r
AUTO-CRUI6E
3 ,23 CONTROL UNIT
7
i
GN D
14
SELF-DIAGNOSIS
COt$NECTOR
10 C-67 c-30 :
FRONT 'SIDE
m piELRq
REVERSE ,-SIDE
n
KX35-AC-Ul516-NC
IGNITION SUB 1 ;SIBLE

SWITCHtlGl) LINK
!i Bd-47
q
I
AUTO-CRUISE
CONTROL UNIT L!
0L
c-01 1
J/B
15A
6 C-55
B
1 COLUMN SWITCH
AUTO-CRUISE
CONTROL SWITCH>
CR”
T C-06
I
I 0.85-GW- 0.85-GW
1
\,4
STOP
LIGHT '~------
"ITCH
c-03 OP?“ON ON
+I1 hS3 O
2
0
0.65-G
OPEN
s CONNECTOR
c-02
1
2
IQI E
!5 16
4ci
AUTO-CRUISE c-01
CONTROL UNIT
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 1:4;;1$~”
*,,,’
4-SPEED
AUTOMATIC
;&V&'~;LE
UNIT
--------
JF AUTO-CRUISE
r Y 5v 9 CONTROL UNIT
GNI GND
" n
MPI
CONTROL
UNIT
C-66
m
4-SPEED
AUTOMATIC
-&$$$)ELE
UNIT
C-60
COMBINATION
=I7
c-55 , 10 c-45
J/B '
r
5 c-54
4 ‘cup 667.3
7m
1234
cl
KXJS-AC-UlSlBh-NC El
AUTO-CRUISE
CONTROL-UNIT c-01
- _ - _ - - - . . - - - - - - I I------ - - - - -
1
I---- (l.BL) (2.0L)
II II
1 ‘6 ‘h ‘s
Y5 Y4 5 4
w w
5 I
16 12_------ 18 C-67
w e
" I wI
w
-L
! THROTTLE MOTOR
;g;E&ON ;;iEX;&ON
t
B-02 B-03
MPI C-66
CONTROL
UNIT
AUTO-CRUISE CONTROL SYSTEM L service Adjustkt Procedw&

Nl4FUU
AUTO-CRUISE CONTROL SYSTEM INSPECTION

AUTO-CRUISE CONTROL SWITCH CHECK
(1) Turn the ignition key to ON.
(2) Check to be sure that the indicator light within the switch
illuminates when the cruise control switch is switched ON.
(Turn the cruise control switch to the “CRUISE” position.)
03A0258 AUTO-CRUISE CONTROL SETTING CHECK

J
(1) Switch ON the cruise control switch.
(2) Drive at the desired speed within the range of approxi-
SET mately 40-145 km/h (25-90 mph).
Y (3) Press the SET button.
(4) Check to be sure that the speed is the desired constant
speed when the switch is released, and also check to be
sure that the auto cruise indicator light (tithin the combina-
tion meter) illuminates.
1(
NOTE
If the vehicle speed decreases to approximately 15 km/h
(9 mph) below the set speed, because of climbing a hill for
03AO258
example, the auto-cruise control will be cancelled.
SPEED-INCREASE SETTING CHECK
(‘1) Set to the desird speed.
(2) Turn the control switch to RESUME position.
(3) Check to be sure that acceleration continues while the
switch is hold, and that when it is released the constant
speed at the time when it was released becomes the
driving speed.
NOTE
Even if, during acceleration, the vehicle speed reaches or
03AO250
exceeds the high limit [approximately 145 km/h (90
mph)], acceleration will continue, however, when the
switch is released, the set speed (“memorized speed”) will
SET become the high limit of the vehicle speed. ’ ” ,
SPEED REDUCTION SETTING CHECK
(1) Set to the desired speed.
(2) Press the SET button.
(3) Check to be sure that deceleration continues while the
switch is pressed, and that when it is released the
constant speed at the time when it was released becomes
the driving speed.
NOTE I
03A025t I
When the vehicle speed reaches the low limit [approxi-
mately 40 km/h (25 mph)] during deceleration, the auto-
matic speed control will be cancelled.
14-136 AUTO-CRUISE CONTROL SYSTEM - Service Adjustment Procedures
AUTO-CRUISE CONTROL CANCELLATION CHECK

(1) Set the auto-cruise control. ”
(2) Check to be sure that there is a return to ordinary driving, ‘c
and that the illumination of the auto-cruise indicator stops,
when either of the operations below is performed.
@ The brake pedal is depressed.
@ The clutch pedal is depressed. <M/T>
@ The shift lever is moved to the “N” or “P” range.
aIT>
@ The auto-cruise control main switch is switched OFF.
@ The ignition switch is turned to OFF.
CHECK OF RETURN TO THE SET SPEED BEFORE
CANCELLATION
(1) Set the auto-cruise control.
(2) Check to be sure that the auto-cruise control is cancelled
when either of the operations below is performed.
@ The brake pedal is depressed.
@ The clutch pedal is depressed. <M/i;>
@I The shift lever is moved to the “N” range. <A/T>
(3) Turn the control switch to RESUME position and release
(RESUME switch ONdOFF) while driving at a vehicle
03AQ250 speed of approximately 40 km/h (25 mph) or higher.
(4) After switching RESUME switch to OFF, check to be sure
that there is a return to the auto-cruise control speed before
it will be cancelled and the vehicle will travel at the constant
speed.
A
rdjusting ACCELERATOR CABLE, THROTTLE CABLE AND

AUTO-CRUISE CONTROL CABLE INSPECTION
AND ADJUSTMENT
(1) Remove the link protector. (Refer to P.14140.)
(2) Check that there are no sharp bends and breaks in the
accelerator cable, throttle cable and auto-cruise control
cable.
(3) Turn the ignition switch to the ON position (without starting
the engine) and leave in that condition for approximately 15
seconds.
(4) Leave plenty of play in each cable and temporarily install
adjusting nuts A, B, C and adjusting bolts D.
03A0281
AUTO-CRUISE CONTROL SYSTEM - Service Adjustment Procedures
(5) Adjust with adjusting nut A so when link A hits the stopper,
the accelerator cable play (inner cable play) reaches the
standard value.
Standard value
M/T: O-l mm (O-.04 in.)
A/T: 2-3 mm (.08-.12 in.)
(6) Fix the accelerator cable with the lock nut.
Stopper 13A0360
(7) Adjust with adjusting nut B so when the link B stopper hits
the end of link A, throttle cable play (inner cable play)
reaches the standard value.
Standard value: l-2 mm (.04-.08 in.)
(8) Fix the throttle cable with lock nut and adjusting bolt D.‘
13A0361
(9) Adjust with.adjusting nut C so when the link C stopper hits

the end of link B, the auto-cruise control cable play (inner
cable play) reaches the standard value.
Standard value: l-2 mm (.04-.08 in.)
(lO)Fix the auto-cruise control cable with the lock nut.
(1 l)After adjusting, confirm that throttle valve fully opens and
closes by operating pedal.
INDIVIDUAL PARTS INSPECTION

AUTO-CRUISE CONTROL SWITCH INSPECTION
(1) Remove the knee protector assembly and the lower
column cover.
(2) Disconnect the column switch connector and check the
continuity between the terminals.
O-0: continuity
2OAO402
Neutral
RESUME switch ON 0 0
NOTE
If there is an abnormal condition (any condition not described in the
table above), replace the column switch.
lBAOlS2
14-138 AUTO-CRUISE CONTROL SYSTEM - Service Adjustment Procedures
STOP LIGHT SWITCH/BRAKE SWITCH ItiSPECTlON

(1) Diconnect the connector. 66
(2) Check for continuity between the terminals of the switch. _
m :continuity
Brake switch Stop light siwtch
1 4 2 3
When brake pedal

depressed. 0 0
When brake pedal
not depressed. 0 0
CLUTCH SWITCH INSPECTION

(1) Disconnect the connector.
(2) Check to be sure that there is continuity between
connector terminals when the clutch pedal is depressed.
INHIBITOR SWITCH (“N” AND “P” POSITIONS)

INSPECTION
(1) Disconnect the connector.
(2) Check to be sure that there is continuity between A
connector terminals 8 and 9 when the shift lever is moved
to the “N” or “P” range.
AUTO-CRUISE CONTROL VACUUM PUMP INSPECTION

Inspection of solenoid valves (control valve, release valve)
(1) Remove the auto-cruise control vacuum pump connector.
(2) Measure the resistance value between terminals 0-0
and between 0-0.
Standard value: 50-6OQ
(3) Check that the solenoid valve makes an operating noise
when battery voltage is impressed between terminals
07A0051 0-0 and between 0-0.
(4) If there is a malfunction of the solenoid valve, replace the
auto-cruise control vacuum pump assembly.
Motor inspection
(1) Remove the auto-cruise control vacuum pump connector.
(2) Check that the motor revolves when battery voltage is
impressed between terminals @-@I.
@k
07AOO50
AUTO-CRUISE CONTROL SYSTEM - service Adjustment ~rocehre~
ACTUATOR INSPECTlCfN
(1) Remove the actuator.
(2) Apply negative pressure to the actuator with the! &c&m
pump and check that the holder moves more than 35 ,mm
(1.38 in.). In addition, check that there is no change iii the
position of the holder when negative pressure is main-
tained in that condition.
(3) First install the actuator and then inspect and adjust the
cruise control cable (Refer to P.14-136.).
I ,_
1 I-
07AOO52
35 mm (1.38 in.) or more
VEHICLE-SPEED SENSOR INSPECTION

Refer to GROUP 8-Meters and Gauges for checking of vehicle
speed sensor.
ACCELERATOR SWITCH INSPECTION
Refer to GROUP 21 -Troubleshooting.
14-140 AUTO-CRUISE ‘CONTROL SYSTEM - Auto-cruise Control
AUTO-CRUISE CONTROL N14TLL

@Accelerator cable, throttle cable and
auto-cruise
I- _ control cable
1 (Keter t o P.14-136.)
4-6 Nm
3-4 ft:lbs.
9-14 Nm
7- 10 ft.lbs. \
\ I - \ ‘.\- 4-6 Nm - 11
3-4 ft.lbs.
4-6 Nm
w 3-4 ft.lbs. --Qc ‘”
/ 03AO282 I
17
I
16
68AOlOO
10
Removal steps of actuator Removal steps of sensor and switches

1. Link protector 11. Accelerator switch <A/l>
2. Auto-cruise control cable 12. Stop light switch
3. Accelerator cable 13. Clutch switch <M/l>
4. Throttle cable 14. Inhibitor switch <A/T>
5. Auto-cruise control vacuum pump +e I)+ 15. Auto-cruise control switch
connector +e l + 16. Vehicle speed sensor
6. Auto-cruise control vacuum pump +e l + 17. Auto-cruise control indicator light
7. Link assembly
8. Vacuum hose Removal steps of control unit
9. Clip
IO. Auto-cruise control actuator 18. Cowl side trim
19. Junction block
20. Auto-cruise control unit
NOTE
(2) +* : Refer to “Service Points of Removal”
(4) %l;;to P. 14-63, 77 for throttle position sensor and idle
AUTO-CRUISE CONTROL SYSTEM - Auto-cruise Control 14-141
SERVICE POINTS OF REMOVAL ?trm
NWpBC
15. REMOVAL OF AUTO-CRUISE CONTROL SWITCH

Refer to GROUP 8-Column Switch.
16. REMOVAL OF VEHICLE SPEED SENSOR
Refer to GROUP 8-Meters and Gauges.
17. REMOVAL OF AUTO-CRUISE CONTROL INDICATOR
LIGHT
INSPECTION N14lDCE
l Check the inner and outer cable for damage.

l Check the cable for smooth movement.
l Check the link protector for damage.
CHECKING THE AUTO-CRUISE CONTROL ACTUATOR
Refer to P.14-138.
SERVICE POINTS OF INSTALLATION N14TDDDD
17. INSTALLATION OF AUTO-CRUISE CONTROL INDICA-

TOR LIGHT
16. INSTALLATION OF AUTO-CRUISE CONTROL SWITCH
Refer to GROUP 8-Column Switch.
15. INSTALLATION OF VEHICLE SPEED SENSOR
Refer to GROUP 8-Meter and Gauges.
, d-a:- ;. _‘
PROPELLER =. ’
S H A F T
CONTENTS NlBAA-
PROPELLER SHAFT ........................................ 4 Lubricants ...................................................... 3

Service Specifications .................................... 2
SPECIAL TOOLS ............................................. 3
SPECIFICATIONS ............................................. 2
1
16-2 PROPELLER SHAFT - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NWCA--
Propeller shaft
Type 4 joint propeller shaft
Length x O.D. mm (in.)
Front 707 x 50.8 (27.8 x 2.00)
Center 647.5 x. 50.8 (25.5 x 2.00)
Rear 530.5 x 50.8 (20.9 x 2.00)
Universal joint
Type
No. 1 (front) Cross type
No. 2 (center front) Cross type
No. 3 (center rear) [Lobro joint] Equal velocity type
No. 4 (rear) Cross type
Cross type universal joint bearing Needle roller bearing (oilless type)
Cross type universal joint
Journal O.D. mm (in.) 14.689 (.5783)
Equal velocity joint type Lobro joint (oilless type)
Equal velocity joint size O.D. mm (in.) 94 (3.7)
NOTE
Propeller shaft length indicates the length between the center points of each joint.
SERVICE SPECIFICATIONS NWCB-
Standard value
Journal axial play mm (in.) 0.02-0.06 (.0008-.0024)
Limit
Propeller shaft runout(Dial indicator reading)
Front mm (in.) 0.6 (.024) or less
Center mm (in.) 0.6 (.024) or less
Rear mm (in.) 0.6 (.024) or less
TORQUE SPECIFICATIONS NlBCC--
Items Nm ft.lbs.
Center bearing self locking nut 30-40 22-29
Flange yoke to differential companion flange 30-35 22-25
Center propeller shaft to center yoke 160-220 116-159
Rear propeller shaft to companion flange 160-220 116-159
Companion flange to Lobro joint assembly 30-40 22-29
t
PROPELLER SHAFT - Specifications/Special Tools/Troubleshooting *(g&a
LUBRICANTS ‘) wN$ii%.y,
Specified lubricant h + Quafqtity ; ’ ‘I, ‘. ,b:

Items
Sleeve yoke surface MOPAR Hypoid Gear Oil/API classification As required
GL-4 or higher, SAE 75W-85W
Lobro joint Outer and inner races Repair kit grease As required
assembly ball grooves , . . ‘*
Rubber packing ,^
Lobro joint assembly Repair kit grease 45-55 g

inner part (1.59-1.94 oz)
Center bearing front and rear grease MOPAR Multi-mileage Lubricant As required
grooves and dust seal lip Part No. 2525035 or equivalent
Shafts and grease sumps of journal,
dust seal lips and needle bearings
SPECIAL TOOLS NlBDA--
TROUBLESHOOTING NWEAAB
Noise at start Worn journal bearing Replace

Worn sleeve yoke spline
Loose propeller shaft installation Retighten
Noise and vibration Unbalanced propeller shaft Replace

at high speed Worn journal bearing
Improper snap ring selection Adjust the clearance
16-4 PROPELLER SHAFT - Propeller Shaft
PROPELLER SHAFT
NlffiA--
Removal steps
1. Self locking nut
l * 2. Insulator
*I)+* 3. Spacer
+e l + 4. Propeller shaft
-- .-...
ii-29 ftlbs.
NOTE
(1) Reverse the removal procedures to reinstall. lOAOOO4
(2) +* : Refer to “Service Points of Removal”.
Mating marks /, SERVICE POINTS OF REMOVAL NlEGBAH
3. REMOVAL OF SPACER
The number of spacers used on each vehicle differs. Check
the number of spacers used and write it down for reference
during reassembly.
4. REMOVAL OF PROPELLER SHAFT
Make mating marks on the differential companion flange
and flange yoke.
lOD505
LBbro joint Caution

1. Remove the propeller shaft in a straight and level
manner so as to ensure that the boot is not damaged
through pinching.
NOTE
Damage to the boot can be avoided, and the work will be
easier, if a piece of cloth or similar material is inserted in the
boot.
boot pinching Cloth
PROPELLER SHAFT - Propeller Shaft
2. Do not lower rear end of the vehicle as the oil will flow
out of the transfer.
3. Be cautious to avoid damage to the oil seal lip of the
transfer.
4. ,.Use the special tool provided as a cover to prevent the
entry of foreign objects into the transfer.
INSPECTION Nl5GCAH
l Check the sleeve yoke, center yoke and flange yoke for
wear,. damage or cracks.
l Check the propeller shaft yokes for wear, damage or
cracks.
l Check the propeller shaft for bends, twisting or damage.
l Measure the propeller shaft runout with a dial indicator.
Limit:
Front propeller shaft 0.6 mm (.024 in.) or less
Center propeller shaft 0.6 mm (.024 in.) or less
Rear propeller shaft 0.6 mm (.024 in.) or less
NOTE
Set the V-blocks as much as possible to the end of the
shaft. Measure deflection at the center of the shaft.
l Check the universal joints for smooth operation in all
directions.
l Check the center bearing for smooth movement.
l Check the center bearing mounting rubber for damage or
deterioration.
lOW504 lOW5OC
SERVICE POINTS OF INSTALLATION NWGOAO
4. INSTALLATION OF PROPELLER SHAFT

(1) Apply the specified gear oil to the sleeve yoke.
Specified oil: MOPAR Hypoid Gear Oil/API classi-
fication GL-4 or higher, SAE 75W-
85W
lOGO
16-6 PROPELLER SHAFT - ProDeller Shaft
r
Mating marks (2) Install the propeller shaft to the companion flangeSwith
\ // the mating marks properly aligned.
Caution
Tighten installation bolts after removing oil and
grease from threads to prevent them from loosen-
ing due to lubrication.
1ODSOS
3. INSTALLATlON OF SPACER/Z. INSULATOR

Spacer
Install spacers and insulators as indicated in the illustration.
Lower Caution
When installing the center bearing, assemble the same
spacers as removed from it (or new spacers of equal
thickness).
Upper
1060012
PROPELLER SHAFT
e-, DISASSEMBLY AND REASSEMBLY
160420 Nm
30-40 Nm
22-29 ft.lbs.
160-&O Nm
116-159 ft.lbs.
Disassembly steps
l *+* 1. Snap ring
+I) l + 2. Journal bearing
++ 3. Journal
4. Flange yoke
5. Sleeve yoke
6. Front propeller shaft
41) +4 7. Lobro joint assembly installation bolt
~~ +4 8. Self locking nut
4r)+4 9. Center yoke
a* l + 10. Companion flange
~~ 11. Rubber packing
++ I)+ 12. Center bearing assembly
13. Rear propeller shaft
l I 14. Snap rjng
+* l + 15. Lobro fount assembly
H 16. Rubber packing NOTE
~~ l + 17. Boot band (1) Reverse the disassembly procedures to reassemble.
++ 18. Lobro joint boot (2) ++ : Refer to “Service Points of Disassembly”.
~~ 19. Washer (3) l : Refer to “Service Points of Reassembly”.
20. Center propeller shaft (4) m : Non-reusable parts
l-
SERVICE POINTS OF DISASSEMBLY Ni6SfhK

(1) Make mating marks on the yoke and universal joint that
is to be disassembled.
(2) Remove the snap rings from the yoke with snap ring
pliers.
lOS511
Journal 2. REMOVAL OF JOURNAL BEARING

Force out the journal bearings from the yoke with a special
tool by the following procedures.
@ Install the collar to the special tool proper.
M B9908 @ Press the journal bearing by using the special tool to
force out the journal bearing on the opposite side.
@ Pull out the journal bearing from the yoke.

NOTE
If the journal bearing is hard to remove, strike the yoke
with a plastic hammer.
@I Press the journal shaft by using the special tool to force
out the remaining bearings.
@ Pull out the journal.
7. REMOVAL OF LOBRO JOINT ASSEMBLY INSTALLA-

U\l
-Mating
Lijbro joint
marks/assembly TION BOLT
(1) Place mating marks on the companion flange and Lobro
joint assembly.
(2) Remove the Lobro joint installation bolts and separate
the Lobro joint from the companion flange.
8. REMOVAL OF SELF LOCKING NUT/S. CENTER YGKE/

10. COMPANION FLANGE/lZ. CENTER BEARING
ASSEMBLY
(1) After placing mating ma,rks on the center yoke and
center propeller shaft, and companion flange and rear
propeller shaft, remove the self locking nuts, then
remove the center yoke and companjon. flange.
NOTE
Be careful not to damage or deform the dust seals on
center propeller shaft assembly and rear propeller shaft.
(2) After placing mating marks. on the center bearing
assembly (front) bracket and center propeller shaft, and
the center bearing assembly (rear) bracket. and rear
propeller shaft, remove the center bearing! ‘bracket.
Caution
The mounting rubber canndt b& rimoved’ frbm the
center bearing bracket.
(3) Pull out the front and rear center bearings with a
commercially available puller.
15. REMOVAL OF LOBRO JOINT ASSEMBLY

(1) Remove the Lobro joint boot from the Lobro joint
assembly.
Mating marks I 1 (2) Remove the Lobro joint assembly as follows:

@ Put mating marks on the outer race, cage and inner
race with a scriber.
@ Remove the outer race and balls.
Caution
Note the positions of balls so that they can be
reinstalled in their’ original positions.
@ Remove the inner race with cage from the center

, Caae propeller shaft by using a commercially available
puller.
NOTE
When changing the grease on the Lobro joint
assembly, wipe off the grease and clean the outer
and inner races, cage and balls.
(3) If the outer race cannot be removed, remove the
Ldbro joint
/ assemblv complete Lobro joint assembly from the center prop-
eller shaft by using a commercially available puller.
commercially avail
10x0021
17. REMOVAL OF BOOT BAND

Caution
Be careful not to damage the Liibro joint boot when the
boot band is loosened.
INSPECTION NWGCAF
l Check the propeller shaft splines for wear or damage.

l Check the ball grooves in inner and outer races for uneven
wear, damage or rust.
l Check ball surface for rust, wear or other damage.
l Check the cage for rust or damage.
10x0018
SERVICE POINTS OF REASSEMBLY NlOGHAP
19. INSTALLATION OF WASHER /18. LOBRO JOINT BOOT/

17. BOOT BAND/lG. RUBBER PACKING/ 15. LOBRO
JOINT ASSEMBLYI14. SNAP RING
(I) Put the washer and boot band on the center propeller
shaft.
(2) Wrap the splined end of center propeller shaft with
adhesive tape.
Washer
Tape I
(3) Install the Lijbro joint boot on the center propeller shaft
and then remove the adhesive tape on the splined, end
of the propeller shaft.
PROPELLER SHAFT - ProDeller Shaft IS-91
(4) Assemble the Lobro joint as follows:
@ Apply a thin coat of the specified grease to the ball
grooves of the inner and outer races.
Specified grease: Repair kit grease ._,
10X0018
Inner race I Ball @ Put the cage on the inner race with the mating
marks aligned and install two balls, one in a groove
and the other in the groove opposite to that groove.
Both balls should be placed in the grooves where
they were before disassembly.
@ Assemble the inner race and cage in the outer race
Recessed end with their mating marks aligned.
of inner race
Chamfered en NOTE
Make sure that the recess.ed end (where snap ring
will be fitted) of the inner race, the recessed end
(where packing will be fitted) of the outer race, and
the chamfered end of the cage are all on the same
side. Also ensure that the relative positions of the
inner and outer races are as shown in the illustra-
tion.
@I Install the remaining balls in their original; positibns.
@ Check that the outer race rotates on the inner race
smoothly. ‘l.
(5) Apply specified grease to the Lobro joint assembly.

[45-55 g (1.59-1.94 oz.)1
10x0040
Rubber (6) Apply a thin and even coat of the specified grease to the
rubber packing and fit the packing in the boot side end
of the Lobro joint assembly.
Caution
For the L6bro joint assembly, the side that has the
concave part (for the rubber packing) in the outer
race is the Liibro joint boot side.
10x0037
(7) Install the Lobro joint assembly on the rear propeller
shaft while aligning their bolt holes, and drive the joint
assembly with a hammer using a socket wrench on the ;r
inner race for complete installation. -4’
10X0036
Mounting bolts (8) Secure the inner race with the snap ring.
(9) Realign the bolt holes in the boot and Lobro joint
assembly utilizing the mounting bolts and fit the boot on
the joint assembly.
Lijbro joint boot

lOUOO16
Boot band 1 (1O)Secure the boot with the boot band.

clip position1 A Caution
Position the boot band clip on the side opposite to
the bosses which are provided in the boot for A
ventilation. Be sure to remove grease, if present, ’ _
from around the bosses. Grease obstructs the
ventilation air passage.
(11)Check that the Lobro joint assembly moves smoothly.
.:,q,,<P#
1ouoo17
12. INSTALLATION OF CENTER BEARING ASSEMBLY
(1) Apply multipurpose grease to the center bearing front
and rear grease grooves and to the dust seal lip.
Rubber mount
/ Part No. 2525035 or equivalent
(2) Be sure to fit the bearing into the rubber mount groove
on the center bearing bracket. e;
Dust seal NOTE -4
- Face the bearing dust seal to the side of center bearing
bracket mating mark.
(3) Assemble the center bearings to the center propeller
10x0001 shaft and rear propeller shaft.
NOTE
Face the side onto which the center bearing bracket
mating mark is placed and the dust seal is in,stalled to
the side of the center propeller shaft and rear.propeller
shaft.
11. INSTALLATION OF RUBBER PACKING/lo. COMPAN-

ION FLANGE/S. CENTER YOKE/8. SELF LOCKING NUT
(1) Apply a thin and even coat of the specified grease to the
rubber packing and fit the packing on the companion
flange.
10X0032
(2) Align the mating marks on the center propeller shaft

and center yoke, and the rear propeller shaft and
companion flange, then press fit the center bearing
with self locking nuts, tightening to the specified
torque.
,.
7. INSTALLATION OF LOBRO JOINT ASSEMBLY INSTAL-

LATION BOLTS
(1) Secure the companion flange and Lobro joint assembly
with installation bolts.
(2) Check for grease leakage from the Lobro joint boot and
companion flange installation parts.
3. JOURNAL/2. JOURNAL BEARING

(1) Apply multipurpose grease to the following parts of the
universal joint kit.
@ Shafts and grease sumps of journal
@ Dust seal lips
@ Needle roller bearings
Caution
Do not apply excessive grease. Otherwise, faulty
fitting of bearing caps and errors in the selection of
1 OY607 snap rings may result.
(2) Press fit the journal bearings to the yoke by using the
special tool according to the following procedures. N
@ Install the base to the special tool proper.
@ Insert both bearings in the yoke, and hold and press -*”
MB990 fit them by using the special tool.
Mating
marks
I MB996840 ,oy)ox
1. INSTALLATION OF SNAP RINGS

(1) Install snap rings of the same thickness onto both sides
of each yoke.
(2) Press the bearing and journal into one side by using a
brass bar with a diameter of 15 mm (.59 in.).
1090014
(3) Measure the clearance between the snap ring and the
groove wall of the yoke with a filler gauge.
If the clearance exceeds the standard value, the snap
rings should be replaced. +
Standard value: 0.02-0.06 mm (.OOOS-.002! in.) .
1 pq
,s I’
REAR
SUSPENSION
CONTENTS N17AA-
<FWD> <AWD>
LATERAL ROD ................................................. 11 REAR SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . 21
REAR AXLE HUB ............................................ 14 SHOCK ABSORBER ASSEMBLY ................... 32
REAR SUSPENSION ASSEMBLY .................. 5 SERVICE ADJUSTMENT PROCEDURES ....... 20

Rear Wheel Alignment Inspection ................ 20
SERVICE ADJUSTMENT PROCEDURES....... 3
Rear Hub Rotary-Sliding Resistance SPECIAL TOOLS ............................................. 18
(Torque) Adjustment ..................................... 4
SPECIFICATIONS ............................................. 16
Rear Wheel Alignment Inspection ............... 3
Wheel Bearing End Play Adjustment ..........
SHOCK ABSORBER ASSEMBLY ...................

3
8
Service Specifications ...................................
Torque Specifications ...................................
16
17
L
Lubricant ....................................................... 17
SPECIAL TOOL ................................................ 3
SPECIFICATIONS ............................................. 2 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General Specifications .................................. 2 TRAILING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 TROUBLESHOOTING ...................................... 19
Torque Specifications ...................................
TORSION AXLE AND ARM ASSEMBLY.. .... 12 UPPER AND LOWER ARM ............................ 25
17-2 REAR SUSPENSION <FWD> - Specifications
SPECIFICATIONS <FWD>
L
GENERAL SPECIFICATIONS N17CAA
Items Vehicles with 1.8L Engine Vehicles with 2.0L DOHC

Engine j
Suspension system 3-link, torsion axle with coil spring type
Coil spring
Wire dia. x O.D. x free length mm (in.) 10.1 x 105.1 x 336.5 10.2 x 105.2 x 316.5
(40 x 4.14 x 13.25) (40 x 4.14 x 12.46)
[Coil spring identification color] [Light Blue x 11 [Orange x 11
Spring constant N/mm (Ibs./in.) 20 (112.0) 23 (128.8)
Shock absorber
Type Hydraulic, cylindrical, double-acting type
Max. length mm (in.) 495 (19.5) 485 (19.1)

Min. length mm (in.) 315 (12.4) 315 (12.4)
Stroke mm (in.) 180 (7.1) 170 (6.7)
Damping force [at 0.3 m/set. (0.9 ft./set.)]

Expansion N (Ibs.) 800 (176)
Contraction N (Ibs.) 300 (66)
Wheel bearing
Type Unit ball bearing
SERVICE SPECIFICATIONS NI’ICB-A
Standard value
Toe-in (Left-right difference) mm (in.) 0+3 (Of.1 18)
Camber -45’ f 30’
Limit
Wheel bearing end play mm (in.) 0.01 (004) or less
Rear hub rotary-sliding resistance N (Ibs.) 31 (7) or less
Rear hub rotary-sliding torque Nm (ftlbs.) 1.8 (1.30) or less
NOTE
Toe-in and camber cannot be adjusted.
TORQUE SPECIFICATIONS Nl7CGA
Items Nm ft.lbs.
Wheel bearing nut 200-260 144-188
Shock absorber upper mounting nut 40-50 29-36
Shock absorber lower mounting nut 80- 100 58-72
Lateral rod mounting nut (body side) 80-100 58-72
Lateral rod mounting bolt (axle beam side) 100-120 72-87
Trailing arm mounting bolt 100-120 72-87
Piston rod tightening nut 20-25 14-18
Brake hose and tube bracket mounting bolt 17-26 12-19
Caliper assembly mounting nut 50-60 3 6 - 4 3
Rear speed sensor mounting bolt 9-14 7-10
I
Special Tools/Troubleshooting/
REAR SUSPENSION <FWD> - Service Adjujltment Procedures
SPECIAL TOOL N17DA.A
Tool Number Name 1 Use 1

L-451 4 Spring compressor Removal and installation of the coil spring
body
TROUBLESHOOTING NI’IEA-A

Squeaks or other Loose rear suspension installation bolts and nuts Retighten
abnormal noise
Malfunction of shock absorber Replace
Worn bushings
Poor ride Excessive tire inflation pressure Adjust the pressure
Weak or broken springs
Body tilting Weak or deteriorated bushings Replace

REAR WHEEL ALIGNMENT INSPECTION N17FAAC
The rear suspension assembly must be free of worn, loosen or

damaged parts prior to measurement of rear wheel alignment.
Standard value:
Toe-in (Left-right difference) Of3 mm (Of.118 in.)
Camber -45’ + 30’
NOTE
The rear wheel alignment is set at the factory and cannot be
adjusted.
If toe-in or camber is not within the standard value, replace
bent or damaged parts.
WHEEL BEARING END PLAY ADJUSTMENT,7FBA0
1. Inspect the play of the bearings while the vehicle is jacked
up and resting on floor jack.
2. Remove the hub cap and then release the parking brake.
3. Remove the caliper assembly and the brake disc.
4. Check the bearing’s end play.
Place a dial gauge against the hub surface; then move the
hub in the axial direction and check whether or not there is
end play.
Limit: 0.01 mm (.004 in.) or less
NOTE
If the limit value is exceeded, the lock nut should be
tightened to the specified torque and check the end play
again.
5. Replace the rear hub bearing unit if an adjustment cannot
12AO531 be made to within the limit.
17-4 REAR SUSPENSION <FWD> - Service Adjustment Procedures
REAR HUB ROTARY-SLIDING RESISTANCE
(TORQUE) ADJUSTMENT N17FCAC -
1. Inspect the play of the bearings while the vehicle is jacked.

up and resting on floor jack.
2. Release the parking brake.
3. Remove the caliper assembly and the brake disc.
4. After turnina the hub a few times to seat the bearing,

attach a spriig balance to the hub bolt, and, pulling at a 9@
3 angle from the hub bolt, measure to determine whether or
not the rotary-sliding resistance of the rear hub (the
rotary-sliding torque of the rear hub) is the standard value.
Limit:
Rear hub rotary-sliding resistance
31N (7 Ibs.) or less
Rear hub rotary-sliding torque
1.8 Nm (1.30 ft.lbs.) or less
12A0533
NOTE
If the limit value is exceed, loosen the nut and then tighten
it to the specified torque, and check the rear hub
rotary-sliding torque again.
5. Replace the rear hub bearing unit if an adjustment cannot +.
be made to within the limit.
A
REAR SUSPENSION <FWD> - Rear Suspension Assembly 17-5
REAR SUSPENSION ASSEMBLY u

-%. REMOVAL AND INSTALLATION N17GAA
17-26 Nm
12-19 ft.lbs.
9-14 Nm
7- 10 ft.lbs.
l Removal of the Hole Cover
(Refer to GROUP 23-Trims.)
200-280 Nm llAO293
144-168 ftlbs.
@Installation of the Hole Cover
l Checking and Adiustment of Brake
---i D i s c De‘ilection ’
(Refer to GROUP 5-Service Adjust- 40-50 Nm
ment Procedures.) 29-36 ltlbs.
l Checking and Adjustment of Rear
Disc Brake Dragging Torque
(Refer to GROUP &Service Adjust-
ment Procedures.)
l Parking Brake Lever Stroke Adjust- 80-100 Nm*
ment 58-72 ft.lbs.*
ment Procedures.)
Removal steps
W l 1. Rear speed sensor <Vehicles with ABS>
2. Parking brake cable
3. Brake hose and tube bracket
4. Calioer assemblv
5. Brake disc ’
6. Hubcap
l + 7. Wheel bearing nut
8. Tongued washer
9. Rear hub bearing unit
10. Dust shield
4* 11. Lateral rod mounting bolt (body side)
12. Cap
13. Shock absorber upper mounting nut
t: 14. Trailing arm mounting bolt
4* 15. Rear suspension assembly
NOTE
--.. (I) Reverse the removal procedures to reinstall.
(31 ~~ : Refer to “Service Points of Installation”.
(4) q : Non-reusable parts 12AO336
(5) * : Indicates parts which should be temporarily tight-
ened, and then fully tightened with the vehicle In
17-6 REAR SUSPENSION <FVVD> - Rear Suspension Assembly
SERVICE POINTS OF REMOVAL Nl7QBh
1. REMOVAL OF REAR SPEED SENSOR <VEHICLES WITH -~

ABS>
Refer to GROUP 5-Wheel Speed Sensor.
11. REMOVAL OF LATERAL ROD MOUNTING BOLT
(1) Remove the lateral rod mounting bolt.
(2) Secure and hold the lateral rod to the axle beam with
wire, etc.
13. REMOVAL OF SHOCK ABSORBER UPPER ‘MOUNTING

NUTS/14. TRAILING ARM MOUNTING BOLTS/15
REAR SUSPENSION ASSEMBLY
(1) Jack up the torsion axle and arm assembly in order to
raise it slightly.
Caution
1. Always insert a wooden block between the jack
Axle beam receptacle and the axle beam and place the jack
at the center of the axle beam.
2. Make sure that the jack does not contact the
lateral rod.
(2) Remove the shock absorber m,ounting nuts and trailing
arm mounting bolts.
(3) Lower the jack slowly, and then remove the rear
suspension assembly. #-
INSPECTION Nl7QCAL
l Check the trailing arm and axle beam for deformation or

damage.
l Check the torsion bar for damage.
l Check the lateral rod for damage or deformation.
l Check the bushings for cracking, deterioration, or unusual
wear.
Drive out BUSHING REPLACEMENT Nl)GTAE
Bay Arbor
TRAILING ARM BUSHING
(1) Drive out the trailing arm bushing as shown in the
Race illustration.
Caution
The bearing within the special tool should be installed, 7
as shown in the figure, at the race surface nut side of
the bearing.
Bearing
REAR SUSPENSION <FWD> - Rear Suspension Assembly
Press in (2) Press in the bushing into the trailing arm (from ahe
chamfered side of the trailing arm).
(3) Be careful that the bushing hole is at the position’ indicated
in the figure and that the difference in bushing projection
distances does not exceed the following value. : :
Ll - L2 = 0 + 1.0 mm (0 * .04 in.)
Bearing
Chamfered side
12l.0247
CROSS SECT. A-A
LATERAL ROD BUSHING (BODY SIDE)

(1) Drive out the lateral rod bushing as shown in the figure.
(2) Press in the bushing using the special tool so that the
-. amount of projection is equal at the’, left and right. .
NOTE
The replacement of the lateral rod bushing at the axle
beam side is made by the same procedures described in
steps (1) and (2) above.
SERVICE POINTS OF INSTALLATION NI’IGDAU
Wheel 7. INSTALLATION OF WHEEL BEARING NUT

, bearing
nut After tightening the wheel bearing nut, align with the
spindle’s indentation and crimp.
1. INSTALLATION OF REAR SPEED SENSOR <VEHICLES
WITH ABS>
pindle Refer to GROUP 5-Wheel Speed Sensor.
17-8 REAR SUSPENSION <FWD> - Shock Absorber Assembly
SHOCK ABSORBER ASSEMBLY

N17NA-A
40-50 Nm
Post-installation Operation 29-36 ft.lbs.
Removal steps
1. Cap
2. Shock absorber upper mounting nut
:: 3. Shock absorber lower mounting bolt
a* 4. Shock.absorber
NOTE
(I) Reverse the removal procedures to reinstall. 12A0530
(2) ** : Refer to “Service Points of Removal”.
(3) * : Indicates parts which should be temporarily tight-
ened, and then fully tightened with the vehicle in
SERVICE POINTS OF REMOVAL NI’INBAA
2. REMOVAL OF SHOCK ABSORBER UPPER MOUNTING

NUT/3. SHOCK ABSORBER LOWER MOUNTING
BOLT/4. SHOCK ABSORBER
raise it slightly.
Caution
receptacle and the axle beam and place the jack
2. Be sure that the jack does not contact the lateral
rod..
(2) Remove the shock absorber’s upper mounting nuts and
lower mounting bolt, and then remove the shock
absorber.
REAR SUSPENSION <FWD> - ‘Shock Absorber Asset&y “fg$
DISASSEMBLY AND REASSEMBLY NI’IOM-A
Disassembly steps
+e ~~ ?. Piston rod tightening nut
2. Washer
3. Upper bushing (A)
e+ 4. Bracket assembly
5. Upper spring pad
6. Upper bushing (B)
7. Collar
l + 8. Cup assembly
l + 9. Dust cover
10. Bump rubber
l 4 11. Coil spring @3----6
\
12. Shock absorber
12AO328
NOTE
(2) +I) : Refer to “Service Points of Disassembly”.
(3) ~~ : Refer to “Service Points of Reassembly”.
SERVICE POINTS OF DISASSEMBLY NI’IGNAAI

1. REMOVAL OF PISTON ROD TIGHTENING NUT
(1) Before removing the piston rod tightening nut,
compress the coil spring using the special tools.
Caution
Do not use an air tool to tighten the bolt of the
special tool.
12Y626
(2) While holding the piston rod, remove the piston rod
tightening nut.
INSPECTION Nl?GOAAl
l Check the rubber parts for damage.
l Check the coil springs for crack, damage or deterioration.
REAR SUSPENSION <WD> - Shock Absorber Assembly
SERVICE POINTS OF REASSEMBLY Nl7QPA2
11. INSTALLATION OF COIL SPRING

(1) Use the special tool (L-4514) to compress the coil ,“3”
spring and insert it in the shock absorber.
(2) Align the edge of the coil spring to the position of the
shock absorber spring seat as shown.
)il spri
12A0049
Cup assembly 1 9. INSTALLATION OF DUST COVEW8. CUP ASSEMBLY

As shown in the illustration, fit the dust cover to the cup
assembly.
Dd cover
L
I Bracket assembly 4. INSTALLATION OF BRACKET ASSEMBLY/l. PISTON

ROD TIGHTENING NUT
(1) With the position of the bracket assembly as shown in
the figure, tighten the tightening nut to the specified *c,
torque.
(2) Install the coil spring so that the lower edge fits into the
spring seat groove and the upper edge fits into the
spring pad groove, then remove the special tool
(L-4514).
1 Shock absorber lower bushing 12R0140
REAR SUSPENSION <FWD> - Lateral Rod
LATERAL ROD i..* $

x REMOVAL AND INSTALLATION
.<I
N17&-
12A0529
Removal steps NOTE

1. Lateral rod mounting bolt (body side) (2) l 4 : Refer to “Service Points of .lnstallation”.
l + 2. Lateral rod mounting bolt (axle beam side) (3) * : Indicates parts which should be temporalrilv tinht-
3. Lateral rod ened, and then fully tightened with the vei&“e’k
4. Lateral rod bushing the unladen condition.
INSPECTION N170CAAil
l Check the lateral rod for damage or deformation.

l Check the bushings for cracking, deterioration, or Unusual
+.
wear.
NCTE
For information concerning the replacement of the lateral
rod bushing, refer to P.17-7.
SERVICE POINTS OF INSTALLATION N17qAA
Axle beam 2. INSTALLATION OF LATERAL ROD MOUNTING BqLT

(AXLE BEAM SIDE)
Install the lateral rod mounting bolt from the direcTion
17-12 REAR SUSPENSION <FWD> - Torsion Axle and Arm Assembly
TORSION AXLE
17-26 Nm
12-19 ft.lbs.
AND
/3
ARM
/
ASSEMBLY
50-60 Nm
36-23 ft.lbs.
2I
/
Nl’IPA-.
Nm 1’ 200-260 Nm
144-188 ft.lbs.
b
1 lA0293
l Checking and Adjustment of Brake Disc
Deflection
Procedures.) 80-100 Nm*
achecking and Adjustment of Rear Disc 58-72 ft.lbs.*
Brake Dragging Torque
Procedures.)
l Parking Brake Lever Stroke Adjustment
(Refer to GROUP 5 -Service Adjustment
Procedures.)
Removal steps
100-120 Nm*
72-87 ft.lbs.*
4
+I) ++ 1. Rear speed sensor <Vehicles with ABS>
@
100-120 Nm*
72-87 ft.lbs.*
12*0334
2. Parking brake cable

3. Brake hose and tube bracket
l * 4. Caliper assembly
5. Brake disc
6. Hub cap
e+ 7. Wheel bearing nut
8. Tongued washer
+I) *+ 9. Rear hub bearing unit
IO. Dust shield
l 11. Lateral rod mounting bolt (axle beam side)
*I) 12. Shock absorber lower mounting bolt
13. Trailing arm mounting bolt
14. Torsion axle and arm assembly
NOTE
(2) ~~ : Refer to “Service Points of Removal”.
(3j W+ : Refer to “Service Points of Installation”.
(51 * : Indicates parts which should be temporarily tight-
ened, and then fully tightened with the vehicle in
REAR SUSPENSION <FWD> - Torsion Axle and Arm Assemblv 1 T-,l’J
SERVICE POINTS OF REMOVAL NliP9AG
1. REMOVAL OF REAR SPEED SENSOR <VEHICLES W<)TH

ABS>
Remove the caliper assembly and suspend it with a piece
of wire.
9. REMOVAL OF REAR HUB BEARING UNIT
NOTE
Rear hub bearing unit cannot be disassemble.
12. REMOVAL OF SHOCK ABSORBER LOWER MOUNTING
BOLT/lB. TRAILING ARM MOUNTING BOLT/ 14.
TORSION AXLE AND ARM ASSEMBLY
raise it slightly.
Caution
receptacle and the axle beam and place the jack
2. Make sure that the jack does not contact the
lateral rod.
(2) Remove the shock absorber’s mounting bolts and the
trailing arm mounting bolts.
(3) Lower the jack slowly, and then remove the torsion axle
and arm assembly.
INSPECTION N17PCAAa
l Check the trailing arm and axle beam for deformation or

damage.
l Check the torsion bar for damage.
0 Check the bushings for cracking, deterioration, or unusual
wear.
NOTE
For information concerning the replacement of the trailing
Axle
I beam arm bushing, refer to P.17-6.
SERVICE POINTS OF INSTALLATION N17PDAI
11. INSTALLATION OF LATERAL ROD MOUNTING BdLT

(AXLE BEAM SIDE)
Install the lateral rod mounting bolt from the direction
9. INSTALLATION OF REAR HUB BEARING UNIT
Press inner race further until inner race contacts with
spindle end.
7. INSTALLATION OF WHEEL BEARING NUT
nut - After tightening the wheel bearing nut, align with the
1. INSTALLATION OF REAR SPEED SENSOR <VEHICLES
WITH ABS>
-Spindle
14AO419
17-14 REAR SUSPENSION <FWD> - Rear Axle Hub
REAR AXLE HUB

REMOVAL AND INSTALLATION Nl’IMA--
9-14 Nm 50-60 Nm
1 ’
Post-installation Operation 4 7 m6 5
l checking and Adjustment of Brake Disc
Deflection llA0359
Procedures.)
l checking and Adjustment of Rear Disc
Brake Dragging Torque
Procedures.)
l Parking Brake Lever Stroke Adjustment
(Refer to GROUP 5%Service Adjustment
Procedures.)
Removal steps
+* l + 1. Rear speed sensor <Vehicles with ABS>
‘2. Parking brake cable
4* 3. Caliper assembly
4. Brake disc
5. Hubcap
l + 6. Wheel bearing nut NOTE
7. Tongued washer (I) Reverse the removal procedures to reinstall.
8. Rear hub assembly <Vehicles with ABS> (2) +e : Refer to “Service Points of Removal”.
4* 9. Rear rotor <Vehicles with ABS> (3) I)+ : Refer to “Service Points of Installation”.
+I) l + 10. Rear hub bearing unit (4) m : Non-reusable parts
SERVICE POINTS OF REMOVAL NVMBAE
1. REMOVAL OF REAR SPEED SENSOR <VEHICLES WITH

ABS>
R6fer to GROUP 5-Wheel Speed Sensor.
Remove the caliper assembly and suspend it with a piece
of wire.
REAR SUSPENSION <FWD> - Rear Axle’ Hub 1~74s
9. REMOVAL OF REAR ROTOR It z:.
*
Caution
Care must be taken not to ‘scratch-,‘,or other&%&
damage the teeth of the rotor. The .rotor must never be
dropped. If the teeth of the rotor are chipped, resulting
in a deformation of the rotor, it will not be-able to
accurately detect the wheel rotation speed’, and the
system will not function normally.
10. REMOVAL OF REAR HUB BEARING UNIT
NOTE I
Rear hub bearing unit cannot be disassembled.,
INSPECTION NllMCAB
l Check the oil seal for crack or damage.

l Check the rear hub for wear or damage.
SERVICE POINTS OF INSTALLATION N17MDAG
IO. INSTALLATION OF REAR HUB BEARING UNJT

Press inner race further until inner race contacts with
spindle end.
6. INSTALLATION OF WHEEL BEARING, NUT

After tightening the wheel bearing ‘nut, align with the
c. 1. INSTALLATION OF REAR SPEED SENSOR <VEHICLES
WITH ABS>
Slit Refer to GROUP 5-Wheel Speed Sensor.
14A0419
17-16 REAR SUSPENSION <AWD> - Specifications
SPECIFICATIONS <AWD>
GENERAL SPECIFICATIONS Nl’ICA-B jG
Suspension system Double wishbone suspension type
Coil spring
Wire dia. x O.D. x free length mm (in.) 11.0 x 106.0 x 332.5 (.43 x 4.17 x 13.1)
Coil spring identification color Purple x 1
Spring constant N/mm (Ibs./in.) 25.0 (140)
Shock absorber
Type Hydraulic, cylindrical, double-acting type
Max. length mm (in.) 568 (22.4)
Min. length mm (in.) 380 (15.0)
Stroke mm (in.) 188 (7.4)
Damping force [at 0.3 m/set. (0.9 ft./set.)]
Expansion N (Ibs.) 900 (198)
Contraction N (Ibs.) 3 0 0 ( 6 6 )
SERVICE SPECIFICATIONS Nl7CEB
:&
Standard value
Toe-in mm ( i n . ) 3.6+3 (.14f.l18)
Camber -1"33'f30'
REAR SUSPENSION <AWD> - Specifications T7-97
TORQUE SPECIFICATIONS .Nl?GGb
‘2 +’ i
Items Nm ft.lbs.
Rear suspension assembly
Center exhaust pipe to main muffler installation bolt 40-50 29-36
Hook installation bolt IO-15 7-ii
Hanger installation bolt IO-15 7-11
Center exhaust pipe to front exhaust pipe installation nut 30-40 22-29
Rear shock absorber installation nut 40-50 29-36
Differential carrier to differential support member 80-100 58-72
Differential support member to body 110-130 80-94
Brake tube bracket to rear shock absorber 17-26 12-19
Differential carrier to propeller shaft 30-35 22-25
Crossmember bracket to body 70-85 51-61
Crossmember bracket to crossmember 110-130 80-94
Rear brake assembly installation bolt 50-60 36-43
Rear speed sensor installation bolt 9-14 7-10
Jpper and lower arm
Upper arm to crossmember 140-160 101-116
Upper arm to knuckle 60-72 43-52
Lower arm to crossmember 90-I 10 65-80
Lower arm to knuckle 60-72 43-52
[railing arm
Companion flange to rear axle shaft 160-220 116-159
Companion flange to drive shaft 55-65 40-47
Trailing arm to crossmember 140-160 101-116
Upper arm to knuckle 60-72 43-52
Lower arm to knuckle 60-72 43-52
Rear shock absorber (lower) 90-I 10 65-80
Rear brake assembly installation bolt 50-60 36-43
Rear speed sensor installation bolt 9-14 7-10
Ghock absorber assembly
Shock absorber installation nut 40-50 29-36
Shock absorber installation bolt 90-l 10 65-80
Brake tube bracket to rear shock absorber 17-26 12-19
Piston rod tightening nut 20-25 14-18
stabilizer bar
Differential support member to body 110-130 80-94
Crossmember bracket to crossmember 110-130 80-94
Crossmember bracket to body 70-85 51-61
Stabilizer link to stabilizer bar 35-45 2 5 - 3 3 I'-'.
LUBRICANT Nl’ICD-

Lip and inside of the dust cover MOPAR Multi-mileage Lubricant Part No. 2525035 or
(upper and lower arm, stabilizer link) equivalent
17-18 REAR SUSPENSION <AWD> - Special Tools
SPECIAL TOOLS Nl’IDA-B
Tnnl Ntlmher Name I Use
Axle shaft puller
Lower arm bushing

REAR SUSPENSION <AWD> - Suecial TooWTroubleshootina
pnng compressor
TROUBLESHOOTING NIlEA-6
Squeaks or other Loose rear suspension installation bolts and nuts Retighten
abnormal noise
Worn bushings
Upper arms and/or lower arms deformed or

damaged
Trailing arms deformed or damaged
Crossmember deformed or damaged
Poor ride Excessive tire inflation pressure Adjust the pressure

Stabilizer bar and/or stabilizer link deformed or

damaged
Body tilting Weak or deteriorated bushings Replace

Upper arms and/or lower arms deformed or
damaged
Trailing arms deformed or damaged
Crossmember deformed or damaged
17-20 REAR SUSPENSION <AWD> - Service Adjustment Procedures
REAR WHEEL ALIGNMENT INSPECTION N17FDAB is.
Measure the wheel alignment with the vehicle parked on level --’
ground.
The rear suspension and wheels should be inspected for wear’
or damage and repaired prior to measurement of wheel,
alignment.
TOE-IN
(1) Measure the toe-in with a toe-in gauge.
Standard value: 3.6f3 mm (.14+ .I18 in.)
12R0556
(2) If the toe-in is not within the standard value, adjust it by

moving the mounting bolts located on the crossmember
side of the trailing arm.
NOTE
Make the adjustment by moving the left and the right bolts r;hr
equally.
Movement of one division on the scale will cause toe-in
variation of about 2 mm (.08 in.).
CAMBER
-- Upper arm (L.H.)
(1) Measure the camber with a camber/caster/kingpin gauge.
Standard value: -1”33’f30’
(2) If the camber is not within the standard value, adjust it by
moving the mounting bolt located on the crossmember
side of the upper arm.
NOTE
Movement of one division on the scale will cause camber
variation of about 15’.
12A0081
Caution
1. As toe-in will vary 0.9 mm (.035 in.) for every
camber scale adjustment, adjust the toe after
adjusting camber.
2. The difference between the left and the right
camber shall be less than 15’.
REAR SUSPENSION <AWD> - Rear Suspension Assemblv
REAR SUSPENSION ASSEMBLY

5. REMOVAL AND INSTALLATION N17GA-B
l Check of Wheel Alignment
(Refer to P.17-20.)
@Check of Parking Brake Lever Stroke
(Refer to GROUP 5-Service Adjust
ment Procedures.)
l installation of Hole Cover
9-14 Nm
7-10 ft.lbs.
/
12AO640
30-40 Nm
\ 22-29 ft.lbs.
lo-15 Nm
7-l 1 ft.lbs.
Removal steps
1. Shock absorber installation nut
2. Brake tube bracket installation bolt
l + 3. Parking brake cable end
** 4. Caliper assembly
5. Center exhaust pipe !rEeverse the removal procedures to reinstall.
6. Gasket (2) 4e: Refer to “Service Points of Removal”.
7. Gasket (3) l + : Refer to “Service Points of Installation”. ’
+I) l + 8. Propeller shaft installation bolt and nut (4) m : Non-reusable parts
17-22 REAR SUSPENSION <AWD> - Rear Suspension Assembly
40-50 Nm
29-36 ft.lbs.
1 /
80-100 Nm
5 8 - 7 2 fiq T
17-26 Nm
\
12-19 ft.lbs.
t
i
) 30-35 N m
, -22-25
- - - ftlbs.
.-._--.
I
llO-i30 Nm
80-94 ft.lbs. I
\ 50-60 Nm 12AO641
36-43 ft.lbs.
70-85’ Nm
51-61 ftlbs.
70-85 Nm
51-61 ft.lbs. 80-94 ftlbs.
Removal steps
+* 9. Self locking nut
10. Differential support member
11. Crossmember bracket
4* 12. Parking brake cable and rear speed sensor
installation bolt
13. Cable band NOTE
14. Rear speed sensor connector <Vehicles (1) Reverse the removal procedures to reinstall.
with ABS (2) +e : Refer to “Service Points of Removal”.
15. O-ring (3) l : Refer to “Service Points of Installation”.
4* 16. Rear suspension assembly (4) a : Non-reusable parts
REAR SUSPENSION <AWD> - Rear Suspension ~Assembly
SERVICE POINTS OF REMOVAL N17GQAOa

(1) Remove the lock pin, rotate the calipei &&e-@bly
upward, then remove the caliper assembly and secure
it with wire, etc.
Caution
The lock pin has a special grease appl‘ied tq it, so be
sure not to wipe it off, and ensure that the lock pin
stays clean.
14AO520
(2) After removing the caliper assembly, .cover the guide

pin with a cloth, etc.
8. REMOVAL OF PROPELLER SHAFT INSTALLATION

BOLT AND NUT
Place mating marks on the differential carrier companion
flange and the propeller shaft flange yoke.
NOTE
The mating marks should be used as a reference for
re-installation.

(1) Before removing the self’ locking nuts, support the
differential case with a transaxle jack.
(2) Remove the self locking nuts.
12AOlOQ
12. REMOVAL OF PARKING BRAKE CABLE AND REAR

SPEED SENSOR INSTALLATION BOLT
(1) Lower the transaxle jack slightly.
(2) Remove the parking brake cable installation bolts.
NOTE
The task may be made easier by increasing the gap
between the body and the crossmember.
17-24 REAR SUSPENSION <AWD> - Rear Suspension Assembly
16. REMOVAL OF REAR SUSPENSION ASSEMBLY
(1) Supporting the rear suspension assembly with a trans- wt
mission jack, move it toward the rear (in the direction of
the fuel tank). c1
(2) Gradually lower the transmission jack, avoiding contact
with the stabilizer bar and the propeller shaft.
Caution
1. Ensure that the propeller shaft does not bend
greatly.
2. Ensure that the liibro joint does not receive any
shock.
1 NOTE
I The lowering of the rear suspension assembly from the
I transmission jack requires three individuals due to the
amount of weight being handled (one on the differen-
tial, and one on either side of the lower arm).
(3) In order to protect the rear suspension assembly dust
shield, support the lower arm ball joint with a wooden
block.
INSPECTION Nl7GCAM
l Check crossmember for cracks or other damage.
SERVICE POINTS OF INSTALLATION N17GOAR -
8. INSTALLATION OF PROPELLER SHAFT INSTALLATION

BOLT AND NUT
Install the propeller shaft to the differential carrier, ensuring
that the mating marks are aligned.
3. INSTALLATION OF PARKING BRAKE CABLE END

brake NOTE
Connecting a parking brake cable end to parking brake lever
and prying up the parking brake lever, the installation of the
other cable end will be easy.
A0221
’
ice,
REAR SUSPENSION <AWD> - Upper and Lower Arm 17-86
UPPER AND LOWER ARM Nl’ISA-

,.1
-. REMOVAL AND INSTALLATION ;’
-1
Post-installa~o~ O&N tion
140-160 Nm+ /cc?!4
a 12A0381
Upper arm removal steps

4+ 1. Self locking nut
2. Upper arm installation nut
3. Upper arm installation bolt
4. Upper arm
NOTE
Lower arm removal steps (I) Reverse the removal procedures to reinstall.
5. Self locking nut (2) ++ : Refer to “Service Points of Removal”.
4* (3) e+ : Refer to “Service Points of installation”.
+I) H 6. Stabilizer link installation nut [;I p i Non-reusable parts
7. Lower arm installation nut Indicates parts which should be temporarily tight-
8. Lower arm installation bolt ened, and then fully tightened with the vehicle in
9. Lower arm the unladen condition.
SERVICE POINTS OF REMOVAL Nl7S0AA

With the special tool, disconnect the upper arm ball joint
and knuckle.
Caution
While the special tool is being used, do not remove the
self locking nut; only loosen it.
17-26 REAR SUSPENSION <AWD> - Upper and Lower Arm
With the special tool, disconnect the lower arm ball jo’int 3c
and knuckle.
wt
Caution
I 12A0090
6. REMOVAL OF STABILIZER LINK INSTALLATION NUT

Hold the stabilizer link with a wrench and remove the
installation nut.
INSPECTION N17SCAA

l Check the upper arm or lower arm for bend or breakage.
l Check the ball joint dust cover for cracks.
wrench
12A0099 CHECKING OF BALL JOINT FOR STARTING TORQUE
grease.
(2) Deflect side to side the ball joint stud several times.
joint starting torque. “,
Standard value: 2-9 Nm (17-78 in.lbs.)
value, replace the upper and lower arm assembly.
BALL JOINT DUST COVER REPLACEMENT N17s~
, MB990800 (1) Remove the dust cover.

(2) Apply multipurpose grease to the lip and inside,of the dust
Dust cover cover.
Grease: MOPAR Multi-mileage, Lubricant
Snap ring Part No.2525035 or equivalent
(3) :;Fedin the dust cover with special tool until i,, is fully -T
LOWER ARM BUSHING REPVCEMENT N17SFAA
(1) Use the special tool to remove and press fit the bushing,
k
REAR SUSPENSION <AWD> - Upper and Lower Arm
(2) Press fit the lower arm bushing until the:bushing outer p&e
edge flush with the lower arm pipe edge.
i , _: I;.:., .. “-:,, .
Pipe Outer pipe

(II;;’ ( b u s h i n g )
12AOo39
SERVICE POINTS OF INSTALLATION N17SDAA
6. INSTALLATION OF STABILIZER LINK INSTAl!L&?h

NUT
Holding the stabilizer link with a wrench, tighten the self
locking nut so that the protrusion of the stabilizer link
(dimension A indicated in illustration) is within the standard
value.
Standard value: 9-l 1 mm (.364-43 in.) / 8.4
12AOlOO
17-28 REAR SUSPENSION <AWD> - Trailing Arm
TRAILING ARM
9%
r{EMOVAL AND INSTALLATION NlTTA-
9-14 Nm
7-10 ft.lbs.
SO-110 Nm
50-60 Nm 65-80 ftlbs.
3 6 - 4 3 ft.lbs. ! \ /
160-220 Nm
_-_ --- .~~~~ \ \\ /
116-159 ftlbs.
55-65 Nm
40-47 ft.lbs. 5m
3
zdnnecting /
/ 13
60-72 Nrn / -\ “c
43-52 ft.lbs. 10 _
12A0639
Removal steps
1.
Parking cable end Post-installation Operation
4* 2.
Rear brake assembly Kheck of Wheel Alignment
3.
Rear brake disc (Refer to P.17-20.)
4.
Drive shaft and companion flange @Check of Parking Brake Lever Stroke
installation bolt, nut (Refer to GROUP 5-Service Adjust-
4I) l + 5. Self locking nut ment Procedures.)
@Rear Brake Disc Run-out Check
++ 6. Companion flange (Refer to GROUP 5-Service Adjust-
7. Rear speed sensor <Vehicles with ABS> ment Procedures.)
8. O-ring
+I) ++ 9. Rear axle shaft
10. Dust shield
11. Self locking nut (upper arm) NOTE
:: 12. Self locking nut (lower arm) (I) Reverse the removal procedures to reinstall.
13. Parking brake cable and rear speed sensor (2) ++ : Refer to “Service Points of Removal”.
(3) W : Refer to “Service Points of Installation”.
installation bolt (4) m : Non-reusable parts
14. Trailing arm installation bolt, nut (5) * : Indicates parts which should be temporarily tight-
15. Rear shock absorber installation bolt ened, and then fully tightened with the vehicle in
16. Trailing arm the unladen condition.
k.
REAR SUSPENSION <AWD> - Trailina Arm
SERVICE POINTS OF REMOVAL u17mAA
2. REMOVAL OF REAR BRAKE ASSEMBLY
Remove the rear brake assembly installation bolts, then
suspend the rear brake assembly from the vehrcle, with
wire, etc.
12A008’I

With the special tool, secure the rear axle shaft, then
remove the self locking nut.
9. REMOVAL OF REAR AXLE SHAFT

With the special tool, remove the rear axle shaft.
11. REMOVAL OF SELF LOCKING NUT (UPPER ARM)

With the special tool, disconnect the upper arm ball joint
and knuckle.
Caution
12. REMOVAL OF SELF LOCKING NUT (LOWER ARM)

With the special tool, disconnect the lower arm ball joint
and knuckle.
Caution
17-30 REAR SUSPENSION <AWD> - Trailing Arm
Pressure fitting Removal INSPECTION N17TCAA
l Check trailing arm for cracks and deformation. h

l Check bushing for cracks, deterioration and wear.
TRAILING ARM BUSHING REPLACEMENT Nl7TEAA
Use the special tool to remove and press fit the bushing.
J J 12A0305
CONNECTING ROD REPLACEMENT Nl7rFAA

Replace the connecting rod using the following procedure:
Connecting rod
(1) Remove the trailing arm bushing.
(2) Remove the bolt and nut.
Trailing arm bushing

12AO298
(3) Set the special tool onto the trailing arm as shown in the
Bolt B I illustration.
NOTE
(1) Apply lubricant to the sliding portion of the special tool
(at the arrow marked “A” in the illustration).
(2) Install bolt B to the trailing arm, at the point shown in
the figure.
(4) Use a spanner, etc., to turn the portion marked “C” in the
illustration to remove the connecting rod.
MB961254 H 12AO299
(5) Installation of the body (special tool) should be performed

with the screw shaft and guide shaft center lines oriented
as shown in the illustration.
MB991 254
r (6) Apply soapy water to the rubber portion of the connecting

rod.
(7) Reverse the removal procedures to press fit.
REAR SUSPENSION <AWD> - Trailing Arm
(8) Remove the special tool after aligning the holes in the
special tool and trailing arm.
(9) Tighten the bolts and nuts to the specified torque. “’
Tightening torque: 85-110 Nm (81-80 ft.lbs.)
(lO)Press fit the trailing arm bushing. (Refer to P.?7-30.)
<Reference>
Special tool (MB9912541
Bolt
Ml2 - -
LIength 80 mm (3.15 In.)
Guide shaft
/ Screw /shaft
/ MB591 255
12AO338
SERVICE POINTS OF INSTALLATION NlTlDAA
9. INSTALLATION OF REAR AXLE SHAFT/G. COM-

PANION FLANGE/5. SELF LOCKING NUT
(1) Temporarily assemble the rear axle shaft to the ,trailing
arm.
(2) Install the companion flange to the rear axle shaft, then
install the self locking nut.
(3) Hold the rear axle shaft with the special tool so that it
doesn’t turn and tighten the locking nut.
17-32 REAR SUSPENSION <AWD> - Shock Absorber Assembly
SHOCK ABSORBER ASSEMBLY

+4z
REMOVAL AND INSTALLATION NI’INA-B
40-50 Nm
29-36 ft.lbs.
/
l installation of Trunk Room Trim
12AO303
Removal steps NOTE

1. Shock absorber upper installation nut Reverse the removal procedures to reinstall.
2. Brake tube bracket installation bolt
3. Shock absorber lower installation bolt
4. Shock absorber assembly
h
REAR SUSPENSION <AWD> - Shock Absorber Assemblv
DISASSEMBLY AND REASSEMBLY Nl’IGM-B
20-25 Nm
Piston rod tightening nut

Washer
Upper bushing (A)
Bracket assembly
Spring pad
Upper bushing (8)
Collar
Cup assembly
Dust cover
1210360
Bump rubber
Coil spring
Shock absorber
SERVICE POINTS OF DISASSEMBLY N17GNAA2
2. REMOVAL OF PISTON ROD TIGHTENING NUT

(1) Before removing the piston rod tightening nut com-
press the coil spring using the special tools.
Caution
Do not use an air tool to tighten the bolt of the
special tool.
(2) While holding the piston rod, remove the piston rod
tightening nut.
INSPECTION N17GOAA2
l Check the rubber parts for damage.

l Check the coil springs for crack, damage or deterioration.
17-34 REAR SUSPENSION <AWD> - Shock Absorber Assembly
SERVICE POINTS OF REASSEMBLY ; N17GPi4te
12. INSTALLATION OF COIL SPRING

(1) Use the special tools (L-4514) to compress the coi! z
spring and insert it in the shock absorber.
(2) Align the edge of the coil spring to the position of the
shock absorber spring seat as shown.
12A0049
C UP assemblv 10. INSTALLATION OF DUST COVER/S. CUP ASSEMBLY

As shown in the illustration, fit the dust cover to the cup
assembly.
Dud cover
Bracket assembly 1 5. INSTALLATION OF BRACKET ASSEMBLY/Z. PISTON

ROD TIGHTENING NUT
(1) With the position of the bracket assembly as shown in
the figure, tighten the tightening nut to the specified .%
torque.
(2) Install the coil spring so that the lower edge fits into the -
spring seat groove and the upper edge fits into the
spring pad groove, then remove the special tools
(L-4514).
Shock absorber lower bushing 12R0140 I
REAR SUSPENSION <AWD> - Stabilizer Bar
STABILIZER BAR
:
_- REMOVAL AND INSTALLATION / i
rq7lA-
.i; :1
12AO620
70-85 Nm 110-130 Nm
51-81 ft.lbs. 80-94 ftlbs.
-.
9-14 Nm
7-10 ft.lbs.
/4
IL-v \
‘3w 35-45 Nm
25-33 ft.lbg.
Removal steps
1. Self locking nut ‘----e2
:: 2. Crossmember bracket 12A0113
3. Parking brake cable and rear speed sensor meA
installation bolt
4. Stabilizer bracket
5. Bushing
+e l + 6. Self locking nut
7. Joint cup (A)
J-
8. Stabilizer rubber
9. Joint cup (B)
+e l a 10. Self locking nut
++ l + 11. Stabilizer link !ykeverse the removal procedures to reinstall.
12. Joint cup (A) (2) +I) : Refer to “Service Points of Removyl”.
13. Stabilizer rubber (3) l * : Refer to “Service Points of Installation”.
4* 14. Stabilizer bar (4) m : Non-reusable parts
L
17-36 REAR SUSPENSION <AWD> - Stabilizer Bar
SERVICE POINTS OF REMOVAL Nl7ljMB
1. R E M O V A L O F SELF LOCKING NUT/P.

CROSSMEMBER BRACKET
(1) Support the rear suspension assembly with a transaxle
jack.
(2) Remove the self locking nuts and crossmember brack-
ets.

Hold the stabilizer link with a wrench, then remove the self
locking nut.
with wrench
10. REMOVAL OF SELF LOCKING NUT/ 11. STABILIZER

LINK
(1) Hold the stabilizer links with a wrench and remove the
self locking nut.
(2) Remove the stabilizer link.
/
12AOllO
7 14. REMOVAL OF STABILIZER BAR

(1) Lower the transaxle jack slightly, maintaining a gap
between the rear suspension and the body.
(2) Remove the stabilizer bar.
\. 1210111
INSPECTION NOZTCAF

l Check the stabilizer bar for deterioration or damage..
l Check the stabilizer link ball joint dust cover for cracks.
REAR SUSPENSION <AWD> - Stabilizer Bar 17-37
CHECKING OF STABILIZER LINK BALL JOINT FOR START-
ING TORQUE
grease.
(2) Deflect side to side the stabilizer link ball joint stud several
times.
Standard value: 1.7-3.2 Nm (15-28 in.lbs.)
value, replace the stabilizer link.
BALL JOINT DUST COVER REPLACEMENTNozm
(1) Remove the clip ring and the dust cover.
Clip ring
(2) Apply multipurpose grease to the lip and inside of the dust
cover.
Jrpose
-. Part No.2525035 or equivalent
12LO217
(3) Use vinyl tape to tape the stabilizer link where shown in the
illustration, and then install the dust cover to the stabilizer
link.
(4) Secure the dust cover by the clip ring.
\ 12LQ243
SERVICE POINTS OF INSTALLATION Nl7ICAO
11. INSTALLATION OF STABILIZER LINK/ 10. SELF LOCK-

Hold with ING NUT/G. SELF LOCKING NUT
wrench
(1) Hold the stabilizer link ball studs with a wrench and
install the self locking nut (A).
(2) Holding the stabilizer link with a wrench, tighten the self
locking nut(B) so that the protrusion of the stabilizer link
is within the standard value.
12AOlOO
NOTES
STEERING
CONTENTS NISAA-
i;,
MANUAL STEERING GEAR BOX.. ............... 21 Oil Pressure Switch Check.. ...................... 15
POWER STEERING GEAR BOX.. ................. 28 Oil Pump Pressure Test ........................... 14
POWER STEERING HOSES ........................ 46 Stationary Steering Effort Check.. ............... 11
POWER STEERING OIL PUMP .................... 39 Steering Angle Check.. ............................ 10
SERVICE ADJUSTMENT PROCEDURES Steering Wheel Centering ......................... 1 1
<MANUAL STEERING > ........................... 7 Steering Wheel Free Play Check ................ 10
Steering Angle Check .............................. 7 Steering Wheel Return to Center Check.. ..... 11
Steering Wheel Centering ......................... 8 Tie Rod End Ball Joint Starting Torque
Steering Wheel Free Play Check ............ .: .. 7 Check.. ......................... . ...................... 10
Tie Rod End Ball Joint Starting Torque Tie Rod End Bail Joint Variation Check
Check .................................................. 8 (Shaft direction) ..................................... 10
Tie Rod End Ball Joint Variation Check V-Belt Tension Check .............................. 12
(Shaft direction) ..................................... 7 SPECIAL TOOLS ............... . ...................... 6
SERVICE ADJUSTMENT PROCEDURES SPECIFICATIONS ..................................... 2;
< POWER STEERING > ............................. 10
General Specifications .............................. 2
Bleeding ............................................... 13
Lubricants ............................................. 5
Fluid Level Check.. ................................. 12
Sealants and Adhesives ............................ 5
Fluid Replacement .................................. 12
Service Specifications ............. ‘. ............... 2
Torque Specifications, . . . . . . . . . . . . . . . . . ..*.......... 3
STEERING WHEEL AND SHAFT.................. 16
19-2 STEERING - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS NlSCA--
Steering wheel
Steering wheel O.D. mm (in.) 372 (14.6)
Gear box
Steering gear type Rack and pinion
Power steering oil pump
Oil pump type Vane type
Displacement cm3/rev. (cu.in./rev.) 9.6 t.59)
Relief set pressure MPa (psi) 8 (1,138)
MANUAL STEERING NlSCB-
Standard value
Steering angle
Inner wheel 37000’ * 20
Outer wheel 3OOOO’
Tie rod end ball joint starting torque Nm (in.lbs.) 0.5-2.5 (4-22)
Assembly dimension of lower column tube mm (in.) 24.8-25.2 (.98-,991
Total pinion torque Nm (in.lbs.)
From O-90” 0.6-l .3 (5-l 1 I
From 90”-650” 0.2-l .o (2-9)
Tie-rod joint swing resistance N (Ibs.) 8-20 (I .8-4.4)
Tie-rod joint swing torque Nm (in.lbs.) 2 - 5 (17-43)
Limit
Steering wheel free play mm (in.) 30 (1.2)
Variation of tie rod end ball joint shaft direction mm (in.) 1.5 l.059)
POWER STEERING
Standard value
Steering wheel free play (with engine stopped) mm (in. 11 (.43)
Steering angle
Turbo <A/T>
Inner wheel 31"30'+2"
Outer wheel 27"OO'
Other models
Inner wheel 35"00'f2"
Outer wheel 29"20'
Tie rod end ball joint starting torque Nm (in.lbs.) 0.5-2.5 ( 4 - 2 2 )
Stationary steering effort N (Ibs.) 37 (8) or less
Assembly dimension of lower column tube mm (in.) 24.8-25.2 (.98-.99)
V-belt deflection mm (in.) 6 - 9 (.24-.35)
i’.g=s
STEERING - Specificdions “,.
items Specifications
-
Oil pump pressure MPa (psi.)
Pressure gauge valve closed 7.5-8.2 (1,067-1,166)
Pressure gauge valve opened 0.8-I .O (114-142)
Oil pressure switch operating pressure MPa (psi1
Oil pressure switch contacts closed (continuity) 1.5-2.0 (213-284)
Oil pressure switch contacts opened (no continuity) 0.7-1.2 (100-171)
Total pinion torque Nm (in.lbs.) 0.6-I .3 (5-l 1)
Tie-rod joint swing resistance N (Ibs.1 8-20 (1.9-4.6)
Tie-rod joint swing torque Nm (in.lbs. 1 2 - 5 (17-43)
Limit
Steering wheel free play (when hydraulic operation) 30 (1.2)
mm (in.)
Variation of tie rod end ball joint shaft direction m m (in.) 1.5 (.059)
Oil pump pressure
Pressure gauge valve opened MPa (psi) 1.5 (213)
Space between vane and rotor mm (in.) 0.06 i.0024)
Shaft backlash of pump body bushing and pulley assembly 0.1 i.004)
mm (in.)
TORQUE SPECIFICATIONS NlSCC--
c. Items Nm ftlbs.
Steering wheel and shaft

Steering wheel lock nut 35-45 25-33
Lower bracket 8-12 6-9
Tilt bracket installation bolt 8-12 6-9
Joint assembly 15-20 11-14
Column support 8-12 6-9
Column tube clamp 4-5 3-4
Manual steering gear box

Joint assembly to gear box 15-20 a 11-14
Tie rod end to knuckle 24-34 17-25
Stabilizer bar bracket 30-42 22-30
Center member to body 80-l 00 58-72
Front exhaust pipe to rubber hanger IO-15 7-l 1
Front exhaust pipe mounting bolt 30-40 22-29
Front exhaust pipe mounting nut 30-40 22-29
Gear box mounting bracket to crossmember 60-80 43-58
Tie rod end lock nut 50-55 36-40
Tie rod to rack 80-100 58-72
Rack support cover locking nut 50-70 36-51
Top plug locking nut 50-70 36-51
19-4 STEERING - Specifications
Items Nm I ft.lbs.
Power steering gear box
Joint assembly 15-20 11-14
Pressure hose to gear box 12-18 9 - 1 3
Return tube to gear box 12-18 9-13
Stabilizer bar bracket 30-42 22-30
Centermember to body 80-100 58-72
Front exhaust pipe to rubber hanger 10-15 7-11
Front exhaust pipe mounting bolt 30-40 22-29
Front exhaust pipe mounting nut
<FWD> 30-40 22-29
Gear box mounting bracket to crossmember 60-80 43-58
Tie rod end lock nut 50-55 36-40
Tie rod to rack 80-100 58-72
Feed tubes 12-18 9-13
End plug 50-70 36-51
Pinion and valve assembly to self-locking nut 20-30 14-22
Rack support cover locking nut 50-70 36-51
Valve housing installation bolts 17-26 12-19
Power steering oil pump
Pressure hose to oil pump 14-21 10-15
Oil pump to oil pump bracket 35-45 25-33
Heat protector installation nut 9-14 7-10
Oil pump bracket to engine
1.8L Engine
Front side 27-41 20-30
Left side 25-33 18-24
2.0L DOHC Engine 25-33 18-24
Oil reservoir installation bolt 9-14 7-10
Oil reservoir bracket installation bolt 9-14 7-10
Pump cover to pump body 18-22 13-16
Suction connector to pump body 6-10 4-7
Connector to pump body 50-70 36-51
Terminal assembly to pump body 25-30 18-22
ower steering hoses
Cooler tube to body 9-14 7-10
Cooler tube to hood lock stay 4-6 29-43
Cooler tube clamp 3.0-4.5 '2-3
Return tube to body 9-14 7-10
Pressure tube to gear box 12-18 9-13
Return tube to gear box 12-18 9-13
Pressure hose to body 9-14 7-10
Pressure hose to oil pump 14-21 IO-15
Pressure hose to pressure tube 30-40 22-29
Pressure hose bracket 9-14 7-10
STEERING - Smcifications
_’ ” I
LUBRICANTS _ : Nls%D--
Items Specified lubricant Quantity

The sliding part of the MOPAR Multi-mileage Lubricant Part No. 2525035 or As required
bearing equivalent ~ 8’
,i-” ‘i .A
The surfaces of the
bearing spacer
The mating surfaces of
the joint and cover
assemblies
Manual Bellows Silicone grease As required
steering
gear box The toothed surface of MOPAR Multi-mileage Lubricant Part No. 2525035 or
the rack and to the inner equivalent
side of the rack bushing
The toothed surface of
the pinion
The surface of the rack
support that contacts
Inner side of the rack
support spring
Tie rod end dust cover
Power Bellows Silicone grease As required
steering
gear box Bearing MOPAR ATF PLUS (Automatic Transmission Fluid Type
O-ring 7176VAutomatic transmission fluid “DEXRON” or
“DEXRON II”
Oil seal
Special tool (MB991 213)
Pinion and valve
assembly seal ring part
Coating of the rack teeth MOPAR Multi-mileage Lubricant Part No. 2525035 or
face equivalent
Pinion and valve
assembly pinion gear part
Rack support surface in
contact with the rack bar
Tie rod end dust cover .I
Power Power steering fluid MOPAR ATF PLUS (Automatic Transmission Fluid Type 0.9 liter (.95 qt.)
steering oil 7176)/Automatic transmission fluid “DEXRON” or
pump “DEXRON II”
Flow control valve MOPAR ATF PLUS (Automatic Transmission Fluid Type As required
Friction surface of rotor, 7176)/Automatic transmission fluid “DEXRON” or
vane, cam ring and pump “DEXRON II”
cover
O-ring
SEALANTS AND ADHESIVES NWCE--
Items Specified sealant and adhesive
Top plug screw

Manual steering
,.I gear box Rack support cover 3M ATD Part No. 8663 or equivalent
Dust cover
End plug screw
Power steering
gear box Power steering rack support cover screw 3M ATD Part No. 8663 or equivalent
Dust cover
STEERING - Social Tools
SPECIAL TOOLS
Power steering oil Measurement of oil pressure

pressure hose set
pressure gauge
adapter (pump side)
support cover
STEERING - Special Tools/Service Adjustment Procedures <Manual &eerina> l’gkf
Tool Number Name 1 Use
I
MB991213 Rack installer ’ Rack installation :,.
i’I/, ‘, ._
‘#
MB991317 Seal ring installer Compression of the seal rings after

replacement of the pinion seal rings
SERVICE ADJUSTMENT PROCEDURiS

< MANUAL STEERING >
STEERING WHEEL FREE PLAY CHECK NOSFAAE
1. Set front wheels straight ahead.

2.’ Measure the play on steering wheel circumference before
wheels move when slightly moving steering wheel in both
directions.
Limit: 30 mm (1.2 in.1
3. When the play exceeds the limit, check play in steering shaft
connection and steering linkage. Correct or replace.
4. When (3) check provides good results, check the following
to adjust:
l Remove the steering gear box, check and adjust total
13A0282 pinion starting torque.
STEERING ANGLE CHECK NlSFDBFl
1. Set front wheels on turning radius gauge and measure

steering angle.
Standard values:
Inner wheel 37000’ 2 20
Outer wheel 30000’
2. When not within the standard value, it is probably a toe
problem. Adjust toe (refer to GROUP 2-Service Adjusttierit
Procedures) and recheck.
,
TIE ROD END BALL JOINT VARIATION CHECK
(SHAFT DIRECTION) NlSFPAB
1. Hold the ball joint with pliers.

2. Set a caliper gauge as illustrated and measure the dis-
placement with the ball stud compressed.
Limit: 1.5 mm LO59 in.)
3. If the measured displacement exceeds the limit, replace the
tie-rod end.
Caution
Even if the variation is within the limit, check ball joint
starting torque.
19-8 STEERING - Service Adjustment Procedures < Manual Steering>
;EEE;D END BALL JOINT STARTING TORQUE
Nl9FEBCa
1. Disconnect tie rod and knuckle with special tool.

Caution
Be sure to tie the cord of the special tool to the nearby
part-
2. Move ball joint stud several times and install nut on stud.
’ Measure ball joint starting torque.
Standard value: 0.5-2.5 Nm (4-22 in.lbs.1
3. When starting torque exceeds the standard value, replace tie
rod end.
4. When the starting torque is under the standard value, check
for play or ratcheting in ball joint. If none of these, it is still
serviceable.
136005!
STEERING WHEEL CENTERING NlSFNAC

Tape or mark
on steering SIMPLIFIED STEERING WHEEL CENTERING
column cover
Determining Steering Wheel’s Off Center
Tape or mark 1. For the road test, take along chalk or tape and a ruler.
on steering
wheel hub 2. Drive straight ahead on an uncambered level surface.
3. When the vehicle’s wheels are pointing straight ahead, mark
the steering wheel hub and column cover with a chalk or
tape line.
4. Stop the vehicle and line up the marks on the hub and
16A0901 column cover.
5. Place a tape strip or mark on the steering wheel rim.
Dotted lines 6. Hold a ruler next to the rim as shown in the illustration, and
show wheel then steer the steering wheel until it is in the desired centered
position.
7. Record the distance the strip or mark on the rim has moved.
This is how far the steering wheel is off center. If it is more
Tape or mark than 16 mm (518 in.) off center, it can be centered by
on steering indexing it ten degrees towards the center.
wheel rim
nce off-center
16AOOOl ,
Indexing Steering Wheel to Center lt
The steering wheel shaft has 36 splines, allowing the steering
IO0 wheel to be indexed in tendegree increments.
1. Remove the steering wheel.
2. Without disturbing the position of the steering wheel shaft,
re-install the wheel as near on-center as possible.
36 splines
_ i ‘I 9;s
STEERING - Service Adjustment Procedures < Manual Steering>
PRECISIG~ STEERING WHEEL CENTFFJIhll
In general,. the tie rods are adjusted to steer the’front wheels in
the same direction that the steering wheel is off center. If the
steering wheel is off canter to the left, center it by adjusting the
tie rods to make the front wheels steer toward the left, and vice
versa.
Steering wheel off center left
13K710
1. Mark the tie rods and tie rod ends with chalk before
loosening the lock nuts.
2. Hold the tie rod with a wrench and loosen the lock nut.
3. Hold the tie rod end with a wrench and turn the tie rod the
desired number of turns.
For 2O or 6 mm (.25 in.) at the steering wheel rim 115
turn of tie rods
4. Tighten the lock nut to specified torque, taking care not to
turn the tie rod.
13A0289
Off center to left Off center to left
Off center to right Off center to right
Turn both tie rods in the same direction.

19-10 STEERING - Service Adjustment Procedures c Power Steering>
r SERVICE ADJUSTMENT PROCEDURES

<POWER STEERING>
STEERING WHEEL FREE PLAY CHECK NlSFABH
1. With engine running (hydraulic operation), set front wheels

straight ahead.
2. Measure the play on steering wheel circumference before
wheels start to move when slightly moving steering wheel
in both directions.
13A0292 Limit: 30 mm (1.2 in.1
3. When the play exceeds the limit, check for play on steering
1 shaft connection and steering linkage. Correct or replace.
4. If the free play still exceeds the limit value set steering wheel
straight ahead with engine stopped. Load 5 N (1 lb.1 towards
steering wheel circumference and check play.
Standard value (steering wheel play with engine
stopped): 11 mm I.43 in.)
If the play exceeds the standard value, remove steering gear
box and check total pinion torque.
13A0293
r STEERING ANGLE CHECK N19FDBJ
1. Set front wheels on turning radius gauge and measure

steering angle.
Standard values:
Turbo <A/T>
Inner wheel 31”30’+2”
Outer wheel 27”OO
Other models
Inner wheel 35”00’_+2”
i Outer wheel 2990’
2. When not within the standard value, it is probably a toe
problem. Adjust toe (refer to GROUP 2-Service Adjustment
Procedures) and recheck.
TIE ROD END BALL JOINT VARIATION CHECK

(SHAFT DIRECTION) N19FVA8
The inspection procedure for the tie rod end ball joint variation
is the same as for the manual steering system. (Refer to
P. 19-7.)
TIE ROD END BALL JOINT STARTING TORQUE

CHECK NlSFEBD
The inspection procedure for the tie rod end ball joint starting
torque is the same as for the manual steering system. (Refer to
P.19-8.)
STEERING - Service Adjustment Procedures < Power Steering > 1941
STEERING WHEEL CENTERING NlSFIYAF
Center the steering wheel in the same way as the manual

steering. (Refer to P.19-8.1
STATIONARY STEERING EFFORT CHECK NlSFFAI
1. With the vehicle stopped on a flat, paved surface, turn the

steering wheel to the straight ahead position.
2. Start the engine and set it to 1,000 + 100 rpm.
Caution
After checking the engine rpm., there must be a return to
the standard idling rpm.
3. Attach a spring balance to the outer circumference of the
steering wheel and measure the steering force required to
13AO293 turn the steering wheel from the straight ahead position to
the left and right (within a range of 1.5 turns).
Also check to be sure that there is no significant fluctuation
of the required steering force.
Standard value:
Steering effort 37 N (8 lbs.) or less
Fluctuation allowance 6 N (1.3 Iljs.)‘or less
:...
STEERING WHEEL RETURN TO CENTER CHE$$$aE

To make this test, conduct a road test and check as follows.
1. Make both gradual and sudden turns and check the steering
“feeling” to be sure that there is no difference in the steering
force required and the wheel return between left and right
turns.
2. At a speed of 35 km/h (22 mph), turn the steering wheel
90°, and release the steering wheel after 1 or 2 seconds.
If the steering wheel then returns 70” or more, the return
can be judged to the satisfactory.
13AO290
NOTE
There will be a momentary feeling of “heaviness” when the
wheel is turned quickly, but this is not abnormal. (This is
because the oil pump discharge amount is especially apt to
be insufficient during idling. 1
19-12 STEERING - Service Adjustment Procedures <Power Steering >
V-BELT TENSION CHECK NlSFliAl
Pressure of
1. Check to be sure that the belt is not damaged and that the
V-belt is correctly attached to the groove of the pulley.
NOTE
, If there is abnormal noise or belt slippage, check the belt
tension and check for unusual wear or abrasion, or damage,
of the pullev contact surface, and for scars or scratches on
t h e pulley.
2. Press in V-belt at the illustrated position with about 100 N
Water pump (22 Ibs.) and measure deflection.
pulley OlA0059
Standard value: 6-9 mm 1.26.35 in.)
3. If there is a deviation from the standard value range, make
an adjustment of the belt tension by following the procedures
described below.
(1) Loosen bolts A, B and C (for holding the oil pump).
(2) Place a bar or similar object against the body of the oil
pump, and, while manually providing the suitable
amount of tension, adjust the amount of flexion of the
belt.
(3) Tighten bolts A, B and C (for holding the oil pump).
(4) Check the amount of flexion of the belt; readjust if
necessary.
Caution
The check should be made after turning the engine
one time or more in the regular direction of rotation (to
the dght).
FLUID LEVEL CHECK NlSFIAI

Fluid fluctuation
1. Park the vehicle on a flat, level surface, startthe engine, and
then turn the steering wheel several times to raise the
temperature of the fluid to approximately 50-60°C
(122-140°F).
2. With the engine running, turn the wheel all the way to the
left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness.
While engine While engine Check the difference of the fluid level when the engine is
running stopped stopped, and while it is running. If the fluid level changes
13uo139
considerably, air bleeding should be done.
FLUID REPLACEMENT NlSFJAJ
1. Raise the front wheels on a jack, and then support them with
rigid racks.
2. Disconnect the return hose connection.
3. Connect a vinyl hose to the return hose, and drain the oil into
a container.
Return hose Vinyl hose
x ,3Ao,42
-
STEERING - Service -Adjustment Procedures < Power Steering > IgJf~
4. Disconnect the high-tension cable, and then while operating
the starting motor intermittently, turn the steering wheel all;
the way to the left and right several times to drain all of the
fluid.
Caution , 35
Be careful not to position thq high-tension able ye&r the
carburetor or the delivery pipe.
5. Connect the return hoses securely, and then secur& it ,with
the clip.
6. Fill the oil reservoir with the specified fluid up td the Ibwer
position of the filter, and then bleed the air. .’
Specified fluid: MOPAR ATF PLUS (Automatic Transmis-
sion Fluid Type 7176)/Automatic trans-
mission fluid “DEXRON” or “DEXRON II”
BLEEDING NlSFKAG
1. Jack up the front wheels and support them by using a floor

stand.
2. Manually turn the oil pump pulley a few times.
3. Turn the steering wheel all the way to the left and right
several times.
4. Disconnect the high-tension cable, and then, while operating
the starting motor intermittently, turn the steering wheel all
the way to the left and right several times (for 1-5 to 20
seconds).
Caution
1. During air bleeding, replenish the fluid supply so that
the level never falls below the lower positiin @f the
I .“:
eiter.
2. If air bleeding is done while engine is runnind, ‘the air
will be brokeir up and absorbed intti the fluid;‘?ti’ sure
to do the bleeding only while cranking.
5. Connect the ignition cable, and then start the engine (idling).
6. Turn the steering wheel to the left and right until there are
no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is upi
to the specified position on the level gauge.
8. Confirm that there is very little change in the fluid level when
the steering wheel is turned left and right.
9. Check whether or not the change in the fluid level is within

5 mm (.2 in.) when the engine is stopped and when it is
running.
Fluid level change:
within 5 mm (2 in.) Caution
1. If the change of the fluid level is 5 mm I.2 in.) or more,
the air has not been completely bled from the system,
and thus must be bled completely.
2. If the fluid level rises suddenly after the engine is
stopped, the air has not been completely bled.
3. If air bleeding is not complete, there will be abnormal
noises from the pump and the flow-control valve, and
While engine While engine this condition could cause a lessening of the life of the
running stopped l?lrnl?J 3
pump, etc.
19-14 STEERING - Service Adjustment Procedures < Power Steering >
Shut-off valv OIL PUMP PRESSURE TEST Nl9FlAF

Pressure gauge (FW close)
(C-3309-E)
CHECKING THE OIL PUMP RELIEF PRESSURE
I
Temperature 1. Disconnect the pressure hose from the oil pump, and then
\
gauge e’ connect the special tools.
Pressure hoses
\ 2. Bleed the air, and then turn the steering wheel several times
while the vehicle is not moving so that the temperature of
the fluid rises to approximately 50-60°C (122-14OOF).
3. Start the engine and idle it at 1,000 f 100 rpm.
4. Fully close the shut-off valve of the pressure gauge and
measure the oil pump relief pressure to confirm that it is
within the standard value range.
Standard value: 7.5-8.2 MPa (1,067-1,166 psi)
Caution
Pressure gauge shut off valve must not remain closed for
more than 10 seconds.
Re (Mti990994)
5. If it is not within the standard value, overhaul the oil pump.
\ 6. Remove the special tools, and then tighten the pressure hose
Oil pump
to the specified torque.
7. Bleed the system.
7 13AO145
CHECKING THE PRESSURE UNDER NO-LOAD CONDITIONS

Shut-off valve 1. Disconnect the pressure hose from the oil pump, and then
Pressure gauge (FullY ?penl connect the special tool.
2. Bleed the air, and then turn the steering wheel several times
Pressure hoses the fluid rises to approximately 50-60°C (122-14OOF).
3. Start the engine and idle it at 1,000 -t 100 rpm.
4. Check whether or not the hydraulic pressure is the standard
value when no-load conditions are created by fully opening
the shut-off valve of the pressure gauge.
Standard value: 0.8-I .O MPa (114-142 psi)
Limit: 1.5 MPa (213 psi)
5. If it is not within the standard value, the probable cause is
a malfunction of the oil line or steering gear box, so check
these parts and repair as necessary.
6. Remove the special tools, and then tighten the pressure hose
STEERING - Service Adiustment Procedures <Power Steering> 3:945
CHECKING THE STEERING GEAR PETENTION HYDRAULIC
Shut-off valve PRESSURE
-
1. Disconnect the pressure hose from the oil pbmd, and iheh
connect the special tools.
2. Bleed the air, and then turn the steering wheel several times
the fluid rises to approximately 50~60OC (122~14pyF).
3. ‘Start the engine and idle it at 1,000 + 100 rem: .‘,’ .
4. Fully close and fully open the shut-off valve of the pressure
gauge.
5. Turn the steering wheel all the way to the left or right; then
check whether or not the retention hydraulic pressure is the
standard value.
Standard value: 7.5-8.2 MPa (1,067-1,166 psi)
6. When not within the standard value, overhaul the steering
gear box.
Remeasure fluid pressure.
OIL PRESSURE SWITCH CHECK NlSFUAB

Pressure gauge
1. Disconnect the pressure hose from the oil pump, and then
connect the special tools.
c. . 2. Bleed the air, and then turn the steering wheel several times
the fluid rises to approximately 50-60°C (122-14OOF).
3. The engine should be idling.
4. Disconnect the connector for the oil pressure switch, and
place an ohmmeter ,in position.
5. Gradually close the shut-off valve of the pressure gauge and
increase the hydraulic pressure then check whether the
hydraulic pressure that activates the switch is the standard
value.
Standard value: 1.5-2.0 MPa (213-284 psi)
6. Gradually open the shut-off valve and reduce the hydraulic
pressure; then check whether the hydraulic pressure that
deactivates the switch is the standard value.
Standard value: 0.7-1.2 MPa (100-171 psi)
19-16 STEERING - Steering Wheel and Shaft
STEERING WHEEL AND SHAFT

REMOVAL AND INSTALLATION NlL)GA- ‘-

l Checking of Steering Wheel Posi- 7 25-33 ft.lbs.
tion with Wheels Straight Ahead 3
\ \ \
\ 8-i2 Nm ’
11 6 - 9 ft.lbs. 0
15-20 Nm
11-14 ft.lbs.
4
13AO296
Removal steps
1. “,c$t assembly and gear box connecting +4 10. Slide lever <A/T>
11. Cover attaching bolts
l * 2. Horn pad 12. Lower bracket installation bolts
4* 3. Steering wheel 13. Tilt bracket installation bolts
+* ++ 4. Instrument under cover 14. Steering column assembly
5. Foot shower duct and lap shower duct 15. Column support
6. Column cover lower
7. Column cover upper NOTE
8. Cover <AIT> (I) Reverse the removal procedures to reinstall.
I)+ 9. Key interlock cable (steering lock (2) a* : Refer to “Service Points of Removal”.
assembly side) <A/T> (3) +a : Refer to “Service Points of Installation”.
STEERING - Steering Wheel and Shaft
SERVICE POINTS OF REMOVAL NlBGBAS
2. REMOVAL OF HORN PAD

(1) Remove the horn pad attaching screw.
(2) The horn pad can be removed by pressing upward.
3. REMOVAL OF STEERING WHEEL

Remove the steering wheel by using a steering wheel puller.
Caution
Do not hammer on the steering wheel to remove it; doing
so may damage the collapsible mechanism.
1610778
4. .REMOVAL OF INSTRUMENT UNDER COVER

Refer to GROUP 234nstrument Panel.
SERVICE POINTS OF INSTALLATION NlgGDAN

10. INSTALLATION OF SLIDE LEVER/S. KEY !NTERLOCK
CABLE (STEERING LOCK ASSEMBLY SIDE)
Refer to GROUP 21 -Transaxle Control. .::
4. INSTALLATION OF INSTRUMENT UNDER COiiER
Refer to GROUP 23-Instrument Panel.
I
NlBGE-
4 - 5 Nm
3-4;lbs. -6
18-z.
11-14 ft.lbs.
13AO287
Disassembly steps
1. Boot l + 15. Bearing spacer
*+ 2. Cover assembly 16. Column bushing
l * 3. Bearing 17. Column tube tower
l + 4. Joint assembly 4, ,+ 18. Bearing
5. Column switch 19. Snap ring
l , .+ 6. Steering lock installation special bolt 4, 20. Clevis pin
l * l + 7. Steering lock bracket 21. Bushing
+I) l + 8. Steering lock 22. Lower bracket
9. Snap ring
10. Stopper NOTE
~~ 11. Bearing spacer (I 1 Reverse the disassembly procedures to reassemble.
W 12. Column tube clamp (2) +I) : Refer to “Service Points of Disassembly”.
13. Column tube upper (3) I)+ : Refer to “Service Points of Reassembly”.
14. Steering shaft (4) q : Non-reusable parts
‘I
STEERING - Steering Wheel and Shaft
SERVICE POINTS OF DISASSEMBLY NlSGFAK
6. REMOVAL OF STEERING LOCK INSTALLATION SPE-

CIAL BOLTI7. STEERING LOCK BRACKET/8. $EERlNG
LOCK
If it is necessary to remove the steering lock, use ‘a
hacksaw to cut the special bolts at the steering lock
bracket side.
18. REMOVAL OF BEARING

Using a socket wrench or similar tool [30 mm (1.2 in.)
outer diameter], remove the bearing.
Socket
13AO106
20. REMOVAL OF CLEWS PIN

Remove the snap ring and then tap out the clevis pin from
the inner side of the column tube lower.
INSPECTION NlSGGAD
l Check the steering shaft for damage and deformati’on.

l Check the joints for play, damage, or rough movement.
a Check the joint bearing for wear and damage.
l Check the tilt bracket for cracks and damage.,
l Check the column bushing for damage.
l Check the dust cover for damage.
SERVICE POINTS OF REASSEMBLY NlSGHSA
18. APPLICATION OF GREASE TO BEARING

/ T o o l
(1) Apply a coating of multipurpose grease to the sliding
part of the bearing.
Grease
Grease: MOPAR Multi-mileage Lubricsfnt Part
No. 2525035 or equivalent
(2) Press the oil seal into the column tube ‘lower.
15. APPLICATION OF GREASE TO BEARING SPACER
Apply multipurpose grease to the surfaces of the bearing
spacer which contacts the steering shaft. q
Grease: MOPAR Multi-mileage Lubricant P a r t .--.
13AOW
Column tube Column 12. INSTALLATION OF COLUMN TUBE CLAMP

(1) Slide the colum tube and adjust so that dimension A in
the figure is the standard value.
(2) Install the column tube clamp at the position where
the dimension shown in the figure is obtained.
I
Column tube
18.5W.5 mm
(.73-.81 in.)
13AO260
11. APPLICATION OF GREASE TO BEARING SPACER

Apply multipurpose grease to the surfaces of the bearing
spacer which contacts the steering shaft.
Grease: MOPAR Multi-mileage Lubricant P a r t rr.
8. INSTALLATION OF STEERING LOCK/7. STEERING -”
LOCK BRACKET/G. STEERING LOCK INSTALLATION
SPECIAL BOLT
(1) When installing the steering lock- and steering lock
bracket to the column tube, temporarily install the
steering lock in alignment with the column boss.
(2) After checking that the lock works properly, tighten
the special bolts until the head twists off.
Caution
The steering lock bracket and blots must be re-
placed with new ones when the steering lock is
installed.
4. INSTALLATION OF JOINT ASSEMBLY /3. BEARING/
2. COVER ASSEMBLY
(1) Install the cover assembly on the joint assembly.
(2) Fill the inside of the bearing with multipurpose grease.
Grease: MOPAR Multi-mileage Lubricant Part
(3) Install the bearings to the shaft on the joint assembly.
(4) Wrap vinyl tape approximately one and one-half times
around the concave circumferences of the bearings,
and then press fit the bearings into the cover assem- *
bly.
(5) Apply multipurpose grease to the mating surfaces of
the joint and cover assemblies.
STEERING - Manual Steering Gear Box 1’94tf
MANUAL STEERING GEAR BOX

NlSLA--
iI\
30-40 Nm
13A0276
22-29 ft.lbs.
15-20 Nm
11-14 ft.lbs.
Removal steps
1. J,O,Itt assembly and gear box connecting
2. Cotter pin
3. Tie-rod end and knuckle connecting
nuts
4. Tie-rod end
5. Stav
6; Stabilizer bar bracket
7. Front roll stopper mounting bolt
8. Center member rear mounting bolts
+* l + 10. Gear box assembly
l + 11. Mounting rubber
NOTE
(1) Reverse the removal procedures to reinstall. 11 4\
(2) +* : Refer to “Service Points of Removal”.
(3) l * : Refer to “Service Points of Installation”. \L?
(4) 0/ : Non-reusable parts
60-60 Nm
43-58 ft.lbs.
4.
WA0203
19-22 STEERING - Manual Steering Gear Box
SERVICE POINTS OF REMOVAL .dlSLl$iF

Using the special tool, disconnect the tie’ rod from the
knuckle.
Caution
1. Be sure to tie the cord of the special tool to the nearby
part*
2. loosen the nut but do not remove it.
10. REMOVAL OF GEAR BOX ASSEMBLY

(1) Move the rack completely to the right and then remove
the gear box from the crossmember.
(2) While tilting the gear box downward, remove it to the
left.
Caution
When removing the gear box, pull it out carefully and
slowly to avoid damaging the boots.
INSPECTION NlSLCAFa
GEAR BOX FOR TOTAL PINION TORQUE

Using the special tools, rotate the pinion gear at the rate of one
rotation in approximately 4 to 6 seconds to check the total pinion
torque.
Standard value:
From 0-90° 0.6-l .3 Nm (5-11 in.lbs.1
From 90°-650° 0.2-1.0 Nm (2-9 in.lbs.1
NOTE
Measure the pinion torque through the whole stroke of the rack.
If the measured value is not within the standard range, first
adjust the rack support cover, and then check the total pinion
torque again.
If the total pinion torque cannot be adjusted to within the
standard range by adjusting the rack support cover, ,check the
rack support cover, rack support spring, rack support and
replace any parts necessary.
CHECK THE TIE ROD FOR SWING RESISTANCE

(1) Give 10 hard swings to the tie rod.
(2) Measure the tie rod swing resistance with a spring balance.
Standard value: B-20 N (1.8-4.4 Ikw.1
12-5 Nm (17-43 in.lbs.)l
(3) If the measured value exceeds the standard value, replace
13Roo7! tie rod assembly.
NOTE
Even if the measured value is below the standard vglue, the
tie rod which swings smoothly without excessive clay may
be used.
SERVICE POINTS OF INSTALLATION NlSLDAF
11. INSTALLATION OF MOUNTING RUBBER/lo. GEAR BOX

ASSEMBLY
When installing the mounting rubber, align the projection of
J Mow&g clamp the mounting rubber with the indentation in the cross-
member to install the gear box.
STEERING - Manual Steering Gear Box
5i)-55 Nm
36-40 ft.lbs.
58-72 ft.lbs.
13A0275
50-55 Nm
36-40 ft.lbs.
Disassembly steps
1. Tie-rod end locking nut 14. Locking nut
l a 2. Tie-rod end l 4 15. Top plug
W M 3. Dust cover l 16. Oil seal
4. Bellows clip l + 17. Pinion
+I) 5. Bellows band 18. Pinion collar
w 6. Bellows 4~ l 19. Ball bearing
+* 7. Tab washer +* l a 20. Rack
l + 8. Tie-rod 21. Rack bushing
*a Adjustment of total pinion torque 22. Rack housing
9. Locking nut
l 10. Rack support cover
H 11. Cushion rubber NOTE
w 12. Rack support spring (1) Reverse the disassembly procedures to reass&mble.
l 4 13. Rack support (2) +e : Refer to “Service Points of Disassemblk’,‘.
(3) ** : Refer to “Service Points of Reas’sembly
(4) $I : Non-reusable parts
SERVICE POINTS OF DISASSEMBLY NlBLFAQ
3. REMOVAL OF DUST COVER

Remove the dust cover from the tie rod end.
5. REMOVAL OF BELLOWS BAND

Cut the bellows band, and then remove the band.
7. REMOVAL OF TAB WASHER

Unstake the tab washer which fixes the tie rod and rack with
a chisel.
19. REMOVAL OF BALL BEARING

Remove the ball bearing from the pinion.
Pinion
Ball bearing
20.REMOVAL OF RACK
Pull out the rack from the gear housing in the ‘direction
Caution
If the rack is pulled out in the wrong direction, the’bushing
in the gear box may be damaged by the rack tpreads.
13K734
-i
INSPECTION NlBLGAE
l Check the rack support for uneven wear or damage.

0 Check the rack support spring for deterioration.
l Check the oil seal for cracks or damage.
l Check the rack pinion tooth surfaces for wear or damage.
0 Check the ball bearings or pinion bushing for noise, uneven
rotation, or damage.
l Check the rack bushing for damage.
l Check the dust cover for cracks or damage. (
SERWCE POINTS OF REASSEMBLY NlSlHAN

/
20. INSTALLATION OF RACK
Apply a coating of multipurpose grease to the toothed
surface of the rack and to the inner side of the rack bushing,
and then install the rack to the rack housing.
Caution
Take care that the applied grease does not tibyruct the
air passage of the rack bushing.
13AO174 I
19. INSTALLATION OF BALL BEARING
Press fit the ball bearing onto the pinion.
Ball bearing
Pinion
13KO66
1 17. INSTALLATION OF PINION

Apply a coating of multipurpose grease to the toothed
surface of the pinion, and then install the pinion to the rack
housing.
13A0115 1
16. INSTALLATION OF OIL SEAL/15 TOP PLUG

(1) Press the oil seal into the top plug.
Oil seal
Top plug
T,,,” 13R0295
-
19-26 STEERING - Manual Steering Gear Box
(2) Apply specified sealant to the threaded portion of the

top plug.
Specified sealant: 3M ATD, Part No. 8663 or equiva- k
lent \r
13. lr ISTALLATION OF RACK SUPPORT/l2. RACK SUPPORT

‘RING/II. CUSHION RUBBER/IO. RACK SUPPORT
: 3VER
Grease (I) Apply a coating of multipurpose grease to the surface of
the rack support that contacts the rack, and then install
the rack support to the rack housing.
(2) Fill the inner side of the rack support spring with
13AO172 multipurpose grease, and then install the rack support
spring to the rack housing.
(3) Install the rubber cushion to the rack support cover.
(4) Apply a coating of the specified sealant to the threaded -L
part of the rack support cover, and then install the rack .‘.
support cover to the rack housing.
Specified sealant: 3M ATD, Part No.8663 or equiva-
lent
0 ADJUSTMENT OF TOTAL PINION TORQUE

(1 ) Position rack at its center and tighten rack support cover
to 15 Nm (1.5 kgm, 11 ftlbs.).
(2:) In neutral position, rotate pinion shaft clockwise one
turn/4-6 seconds with special tool. Return rack support
cover 30” -60” and adjust torque to the standard value.
Standard value:
From 0-90° 0.6-I .3 Nm (5-l 1 inIbs.
From 90°-650° 0.2-1.0 Nm (2-9 in.lbs.1
Caution
I. When adjusting, set the standard value at its
highest value.
2. Assure no ratcheting or catching when operating
rack towards the shaft direction.
NOTE
When it cannot be adjusted within the specified return
angle, check rack support cover components or replace. A
(3) After adjusting, lock rack support cover with locking nut.
STEERING - Manual Steering Gear Box m-2.7
8. INSTALLATION OF TIE-ROD
After installing tie-rod to rack, fold tab washer end,. (2
locations) to tie-rod notch. ’
13AO175 .‘
6. APPLICATION OF GREASE TO BELLOW

Pack tie rod bellows lock groove with specified grease.
Specified grease: Silicone grease
Grease
136007(1
3. INSTALLATION OF DUST COVER

(1) Pack dust cover interior and lip with multipurpose grease.
(2) Apply specified sealant to dust cover.
Specified sealant: 3M ATD, Part No.8663 or equiva-
lent
(3) Using the special tool, press dust cover to tie-rod end.
2. INSTALLATION OF TIE-ROD END

Screw in tie-rod end to have its right and left ‘length as
illustrated. Lock with locking nut.
184-186 mm
(7.24-7.32 in.)
13ElW
--
19-28 STEERING - Power Steering Gear Box
NlSPA--
POWER STEERING GEAR BOX
-
@Draining of the Power Steering Fluid
@Removal of Transfer 50-65 Nm
:1&&r:, GROUP 21 -Transfer.) 36-47 ft.lbs.
I/a
l Installation of Transfer 3oh2 Nm
(:zD:” GROUP 21 -Transfer.) ^a -aa I. 22-30 ftlba.
l SSy,lying of the Power Steering
au-IUU Nrn I
l Bleedino of the Power Steering IO-15 Nm

Fluid Liie
(Refer to P.19-13.1
l khecking of Steering Wheel Posi- 22-29 ft.lbs.
tion with Wheels Straight Ahead
*Adjustment of the Front Wheel
Alignment
(Refer to GROUP Z-Service Ad-
justment Procedures.)
13A0276
15-20 Nm
11-14 ft.lbs.
Removal steps 12-18 Nm

1. “,;;rt assembly and gear box connecting
bolt
2. Connection for return tube A-34 IUm
3. Connection for pressure hose 1 j-+ft.lbs.
4. Cotter pin K-
4I)
5. Aft-cd end and knuckle connecting
: II I- .5
f3: H,“a:od end
8. Stabilizer bar bracket

/ .2!
9. Front roll stopper mounting bolt
10. Center member rear mounting bolt
1
i!!
44 11. Front exhaust pipe <FWD>
l * l + 12. Gear box assembly
l + 13. Mounting rubber
NOTE
(3) .* : Refer to “Service Points of Installation”.
q : Non-reusable parts
(4) lli
W-W Nm 13A0353
43-58 ft.lbs.
STEERING - Power Steering Gear Box
SERVICE POINTS OF REMOVAL NIBPNAB
6. DISCONNECTION OF TIE-ROD END

Using the special tool, disconnect the tie rod from the
knuckle.
Caution
1. Be sure to tie the cord of the special tool to the nearby
part.
2. Loosen the nut but do not remove it.
Refer to GROUP 2-Stabilizer Bar.
12. REMOVAL OF GEAR BOX ASSEMBLY
(I 1 Move the rack completely to the right and then remove
the gear box from the crossmember.
(2) While tilting the gear box downward, remove it to the
left.
Caution
When removing the gear box, pull it out carefully and
slowly to avoid damaging the boots.
INSPECTION NlSPCADa
GEAR BOX FOR TOTAL PINION TORQUE

Using the special tools, rotate the pinion gear at the rate of one
rotation in approximately 4 to 6 seconds to check the total pinion
torque.
Standard value: 0.6-l .3 Nm (5-l 1 in.lbs.1
NOTE
Measure the pinion torque through the whole stroke of the rack.
If the measured value is not within the standard range, first
adjust the rack support cover, and then check the total pinion
torque again.
lS1017S If the total pinion torque cannot be adjusted to within the
standard range by adjusting the rack support cover, check the
rack support cover, rack support spring, rack support and
replace any parts necessary.
CHECK THE TIE ROD FOR SWING RESISTANCE

(1) Give 10 hard swings to the tie rod. I
(2) Measure the tie rod swing resistance with a spring balance.
Standard value: 8-20 N (1.8-4.4 Ibs.) ’
12-5 Nm (17-43 in.lbs.)l
(3) If the measured value exceeds the standard value, replace
5 tie rod assembly.
NOTE
I / Mounting rubber Even if the measured value is below the standard value, the
tie rod which swings smoothly without excessive play may
be used.
SERVICE POINTS OF INSTALLATION Nl9PDA9
13. INSTALLATION OF MOUNTING RUBBER/lZ. GEAR BOX

ASSEMBLY
When installing the mounting rubber, align the projection of
the mounting rubber with the indentation in the cross-
II Mdting clamp 13Roo77
member to install the gear box.
r
17-28 Nm
17 12,-19 ft.lbs.
Steering gear seal k!t
12-18 Nm
9-13 ftlbs.
Grease
50155 Nm
36-40 ft.lbs.
23;>.
I I 2b
SO-56 Nm
36-40 ft.lbs. I ‘\
80-100 Nm : _
58-72 ft.lbs. / /
mo25a
Disassembly steps
1. Tie rod end locking nut +e l a 21. Ball bearing
l 4 2. Tie rod end l * l * 22. Oil seal
+I) I)+ 3 . D u s t c o v e r l * l 4 23. Circlip
4. Bellows clip 24. Rack stopper
a* 5. Bellows band l * 25. Rack bushing
*a 6. B e l l o w s 4* l * 26. Rack
4, 7. Tab washer l * 27. O-ring
l 4 8. Tie rods +* l + 28. Oil seal
9. Feed tube 29. Seal ring
10. O-rings 30. O-ring
*a Adjustment of total pinion torque ++ l 31. Ball bearing
+* l * II. End plug +W l 32. Needle roller bearing
12. Self-locking nut +* l a 33. Oil seal
13. Locking nut +* l a 34. Back-up washer
l * l _- * 14. Rack support cover 35. Rack housing
-
lb. Hack SUppOrt sprlng
w 16. Rack support NOTE
17. Valve housing (1) Reverse the disassembly procedures to reassemble.
+* l * 18. Oil seal (2) +e : Refer to “Service Points of Disassembly”.
,+ 19. Pinion and valve assembly (3) l + : Refer to “Service Points of Reassembly”.
l + 20. Seal ring
SERVICE POINTS OF DISASSEMBLY NISAK

.4
3. REMOVAL OF DUST COVER
I
Remove the dust cover from the tie rod end.
5. REMOVAL OF BELLOWS BAND

Using a screwdriver or similar tool, loosen and then remove
the boot retaining band.
7. REMOVAL OF TAB WASHER

Unstake the tab washer which fixes the tie rod and rack with
a chisel.
13PO126
11. REMOVAL OF END PLUG

Disconnect end plug caulking and remove end plug.
14. REMOVAL OF RACK SUPPORT COVER

Using the special tool, remove the rack support cover from
the gear box.
18. REMOVAL OF OIL SEAL

Using a plastic hammer, gently tap the pinion to remove it.
13A0284
21. REMOVAL OF BALL BEARING/22. OIL SEAL

Using a socket, remove the oil seal and the ball bearing from
the valve housing simultaneously.
cket
13AO285
23. REMOVAL OF CIRCLIP

(1) Turn the rack stopper clockwise until the end of the
circlip comes out of the slot in the rack housing.
(2) Turn the rack stopper anticlockwise to remove the circlip.
13R0551
26.REMOVAL OF RACK
Pull out the rack slowly.
At this time also take out the rack stopper and the rack
bushing simultaneously.
13R0541
28.REMOVAL OF OIL SEAL

Partially bend oil seal and remove from rack bushing.
Caution
Do not damage oil seal press ftiing surface.
STEERING - Power Steering Gear Box 4 $143

Use a brass bar to remove the ball bearing from the gear
housing.
-)-’
9, I :
>.,I:
13130549
32.REMOVAL OF NEEDLE ROLLER BEARING

Use the special tool to remove the needle roller bearing from
the rack housing.
Caution
Do not open special tool excessively to prevent damaging
housing interior.
13Ro581
33.REMOVAL OF OIL SEAL/34. BACK-UP WASHER

Use a piece of pipe or similar tool to remove the back-up
Pipe washer and oil seal from the gear housing.
Caution
Be careful not to damage the inner surface of the rack
cylinder of the gear housing.
13RO218
INSPECTION NlSPOIO
RACK
0 Check the rack tooth surfaces for damage or wear.
0 Check the oil seal contact surfaces for uneven wear
0 Check the rack for bends.
PlNlON AND VALVE ASSEMBLY
0 Check the pinion gear tooth surfaces for damage or wear.
0 Check for worn or defective seal ring.
BEARING
0 Check for roughness or abnormal noise during bearing
operation.
0 Check the bearing for play.
0 Check the needle roller bearings for roller slip-off.
OTHERS
l Check the cylinder inner surface of the rack housing for
damage. i. ,..
l Cheek the boots for damage, cracking or deterioration.
l Check the rack support for uneven wear or dents.
0 Check the rack bushing for uneven wear or damage.
SERVICE POINTS OF REASSEMBLY NlSPHAV
34. INSTALLATION OF BACK-UP WASHER133. OIL SEAL

Guide (1) Apply a coating of the specified fluid to the outside of the
oil seal.
Specified fluid: MOPAR ATF PLUS (Automatic Trans-
mission Fluid Type 7176)/Automatic
transmission fluid “DEXRON” or
“DEXRON II”
/ Oil seal (2) Using a tool, press the back-up washer and the oil seal
Back-up washer 13A0181
into the rack housing to the specified position (where the
upper surface of the press-in guide coincides with the
stepped part of the press-in tool).
32. INSTALLATION OF NEEDLE ROLLER BEARING
(1) Apply specified fluid to housing, bearing and oil seal
press fitting surface.
roller
“DEXRON II”
(2) Press fit needle roller bearing.
Caution
Press fit straight as valve housing is aluminium.

Press fit ball bearing.
13R0380
28. INSTALLATION OF OIL SEAL/27. O-RING

(I 1 Apply a coating of the specified fluid to the outside of the
oil seal and O-ring.
mission Fluid Type 7176VAutomatic
“DEXRON II”
O-ring
(2) Press fit oil seal until it touches rack bush end.
13R037E
26. INSTALLATION OF RACK ASSEMBLY

(1) Apply a coating of multipurpose grease to the rack teeth
face.
No.2525035 or equivalent
Caution
V&t hole Do not close the vent hole in the rack with grease.
13K583
-
(2) Cover rack serrations with special tool.

(3) Apply specified fluid on special tool.
Oil seal MB991213
transmission fiiid “DEXPON” or
“DEXRON II”
(4) Match oil seal center with rack to prevent reta’iner spring
from slipping and slowly insert rack from power cylinder
Back-up washer
side.
13G014; 7
25. INSTALLATION OF RACK BUSHING ASSEMBLY

Wrap the rack end with vinyl tape, apply a coating of the
specified fluid, and then install the rack bushing and rack
stopper.
mission fluid “DEXRON” or “DWRON II”
Caution
Rack bushing
Do not allow oil seal retainer spring to slip out.
23. INSTALLATION OF CIRCLIP

Insert circlip to rack stopper hole through cylinder hole. Turn
rack stopper clockwise and insert circlip firmly.
Caution
Insert cirdip to rack stopper hole while turning rack
stopper clockwise.
1360148 13K687
22.lNSTALLATlON OF OIL SEAL

Apply a coating of the specified fluid to the outside of the
oil seal. Press the oil seal into the valve’housing.
sion Fluid Type 7176VAutomatic trans-
Apply a coating of the specified fluid to the outside of the
ball bearing. Press the ball bearing into the valve housing.
Seal rings
20,lNSTALLATlON OF SEAL RING /lg. PINION AND
VALVE ASSEMBLY
(1) When installing seal rings, press firmly into valve groove.
Apply specified fluid.
Specified fluid: MOPAR ATF PLUS (Autombtic Trans-
mission Fluid Type 7176)/+tomatic
“DEXRON II”
13A0110
-
NOTE
MB991317 Because the seal rings expand at the time of installation,
use the special tool to compress the seal rings so that -
they are well seated. L
side
13A031f I
(2) Apply multipurpose grease to pinion gear and housing

bearing.
(3) Wrap vinyl tape around the serrated part so that the oil
seal won’t be damaged when the pinion and valve
assembly is installed to the valve housing.
Vinyl tape APP~ (4) Mount the pinion and valve assembly to the valve
automatic
transmission housing.
fluid
13POl44

Using a tool, press the oil seal into the valve housing.
Caution
, Tool
In order to eliminate a seal malfunction at the valve -
housing alignment surface, the upper surface of -the oil
seal should project outward approximatelv 1 mm t.040
in.) from the housing edge surface.
Approx. 1 mm
‘, I
i
(Approx. ,040 in.)
’ 13POO76
16. INSTALLATION OF RACK SUPPORT

Apply multipurpose grease to the rack support surface in
contact with the rack bar.
14. INSTALLATION OF RACK SUPPORT COVER
Apply semi-drying sealant to rack support cover screw. Lock
temporarily with locking nut.
13A014:
I I 11. INSTALLATION OF END PLUG

End plug
I
End plug (1) Apply the specified sealant to the threaded part of the
\ , I end plug.
I
Specified sealant: 3M ATD Part No.6663 or equiva-
lent rL-
(2) Secure the threaded portion of the end plug at two ._
places by using a punch.
Sealant
13K,30
l ADJUSTMENT OF TOTAL PINION TORQUE

(1) Position rack at its center. With special tool, tighten rack
support cover to 15 Nm (11 ftlbs.).
(2) In neutral position, rotate pinion shaft clockwise one
turn/4-6 seconds with special tool. Return rack, support
cover 30°-60° and adjust torque to the stanoard,vaiue.
Standard value: 0.6-l .3 Nm (5-l 1 in.lbs.1
Caution
1. When adjusting, set the standard value at its
highest value.
2. Assure no ratcheting or catching when operating
rack towards the shaft direction.
NOTE
When it cannot be adjusted within the specified return
angle, check rack support cover components or replace.
(3) After adjusting, lock rack support cover with locking nut.
8. INSTALLATION OF TIE ROD

After installing tie rod to rack, fold tab washe;, end (2
locations) to tie rod notch. ‘*,t, \
\
13A017E
I
6. APPLICATION OF GREASE TO BELLOWS

Pack tie rod bellows lock groove with specified grease.
Specified grease: Silicone grease
\
Silicon grease
-r-
MB990776-A 3. INSTALLATION OF DUST COVER
Lip
(1) Pack dust cover interior and lip with multipurpose grease.
(2) Apply specified sealant to dust cover.
Specified sealant: 3M ATD Part No.8663 or equiva-
lent
Sealant
(3) Using the spcial tool, press dust cover to tie rod end.
131564 13A0259
2. INSTALLATION OF TIE ROD END

Screw in tie rod end to have its right and left length as -
illustrated. Lock with locking nut.
I- -l
<FWD> 183.4-185.4mm (7.22-7.30in.)
<AWD> 179.6-181.6mm (7.07-7.15in.)
13ElOO
STEERING - Power Steering Oil Pump 1849
POWER STEERING OIL PUMP
“@ NlgRA-
< 1.8L Engine > 35-45 Nm
25-33 ft.lbs.
0 Draining the Power Steering Fluid
0 Supplying of the Power Steering
Fluid
0 Bleeding the Power Steering Fluid
Line
(Refer to P.79-13.)
0 Checking of the Oil Pump Pressure
(Refer to P.l9-14.) ~
20-30 ft.lbs.
13A0270
9-14 Nm
< 2.0L DOHC Engine > 7-10 ft.lbs.
35-45 Nm \
25-33 ft.lbs.
/
‘/
1
7
35-45 Nm 9-14 Nm
7-10 ft.lbs.
25-33 Nm
18-24 ft.lbs.
13AO269
Removal steps
1. Pressure switch connector
a* 2. Return hose
4* 3. Suction hose
+r) .+ 4. Pressure hose
5. O-ring NOTE
6. V-belt (I) Reverse the removal procedures to reinstall.
7. Oil pump (2) *I) : Refer to “Service Points of Removal”.
8. Oil pump bracket (3) l a : Refer to “Service Points of Installation”.
(4) 0 : Non-reusable parts
9. Heat protector <2.0L DOHC Engine>
10. Oil reservoir
1 1. Reservoir bracket
1 S-40 STEERING - Power Steering Oil Pump
SERVICE POINTS OF REMOVAL Nl8RW
2. DISCONNECTION OF RETURN HOSE

(1) Removal the reservoir cap and disconnect the return
hose from the reservoir to drain the fluid.
(2) Jack up the front wheels.
(3) Disconnect the high tension cable and turn the engine
over several times to drain the fluid from the gear box.
3. DISCONNECTION OF SUCTION HOSE14. PRESSURE

HOSE
Caution
The alternator is located under the oil pump. If any of the
hoses are to be removed, cover the alternator with a rag
to protect it from oil.
INSPECTION NIRCAA
0 Check the V-belt for cracks.

0 Check the pulley assembly for uneven rotation.
SERVICE POINTS OF INSTALLATION NlSRDAH
4. INSTALLATION OF PRESSURE HOSE

Connect the pressure hose so that its slit part contacts the
oil pump’s guide bracket.
STEERING - Power Steering Oil Pumt,
DISASSEMBLY AND REASSEMBLY 137~.-
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit
18-22 Nm
13-16 ft.lbs.
50-70 Nm
36-51 ft.lbs.
1
I \ =--=x=-T--
6-10 Nm
4 - 7 ft.lbs.--
25-30 Nm ’ \ 13A0351
16-22 ft.lbs.
25m 29
Disassembly steps
I)+ 1. Pumpcover 19. Snap ring
l + 2. O-ring 20. Terminal
l 4 3. Cam ring 21. Washer
l 4 4. Vanes 22. Insulator
l + 5. Snap ring l + 23. O-ring
l 4 6. Rotor 24. Plug
4* 7. Pulley assembly l 25. O-ring
l 8. Side plate l 26. Spring
I)+ 9. O-ring 27. Plunger
l a 10. O-ring 28. Piston rod
11, Suction connector 29. Oil pump body
l + 12. O-ring
+4 13. Oil seal
14. Connector
l + 15. O-ring FyEeverse the disassembly procedures to reassemble.
l + 16. Flow control valve (2) ~~ : Refer to “Service Points of Disassembly”.
17. Flow control spring (3) l + : Refer to “Service Points of Reassembly”.
18. Terminal assembly
19-42 STEERING - Power Steering Oil Pump
SERVICE POINTS OF DISASSEMBLY NleRFAM
7. REMOVAL OF PULLEY ASSEMBLY %

Tap the rotor side of the shaft lightly with a plastic hammer, ,,~
and take out the pulley assembly.
INSPECTION NlSRGAK
0 Check the flow control spring for wear.

0 Check the shaft of the pulley for wear and bend.
0 Check the groove of rotor vane for “stepped” wear.
0 Check the contact surface of cam ring and vanes for
“stepped” wear.
0 Check the vanes for breakage.
CHECK OF GAP BETWEEN VANE AND ROTOR GROOVE

Install vane to rotor groove as illustrated. Measure the gap
between vane and rotor groove with thickness gauge.
Limit: 0.06 mm (.0024 in.) ?A
CHECK OF SHAFT BACKLASH OF PUMP BODY BUSHING

AND PULLEY ASSEMBLY
(1) Place a dial gauge at the end of the shaft of the pulley
assembly.
(2) Move the pulley assembly up and down, and measure the
play.
Limit: 0.1 mm I.004 in.)
SERVICE POINTS OF REASSEMBLY NlSRHBH
26. INSTALLATION OF SPRING

Fit the spring to the oil pump body with the larger-diameter
end at the terminal assembly side.
A.
13A0279
STEERING - Power Steering Oil Pump
25.123. INSTALLATION OF O-RINGS

Apply specified fluid on O-rings to install.
mission fluid “DEXRON” or “DGXRON II”
I No. I I.D. x Width mm (in.) 1 Identification color 1

1 13 x 1.9 t.51 x .0748) Blue
Terminal assembly 2 3.8 x 1.9 l.15 x .0748) -
13K753
16. INSTALLATION OF FLOW CONTROL VALVE

Mark A,B or C -43
(1) If the flow control valve is to be replaced, install the flow
control valve to the oil pump body corresponding with
the body identification mark (A, 6, C).
(2) Apply the specified fluid to the outside of the flow control
valve.
mission Fluid Type 7176)/htomatic
Mark A,B or C transmission fluid “DEXRON” or
“DEXRON II”
13G0151
15. INSTALLATION OF O-RINGS
Apply specified fluid on O-rings to install.
mission fluid “DEXRON” or “DlkXRON II”
No. I.D. x Width mm (in.) ldentificaqion color

1 I 1 x 1.9 t.43 x .0748) Yelllow
/
Connector 2 13x 1.9 l.51 x .0748) Blue
3 1 7 . 8 x 2.4 j.70 X .0945) -
13K752 4 13.5 x 1.5 t.53 x .0590) Red

Drive the oil seal into the pump body.

Apply specified fluid on O-ring to install.
Specified fluid: MOPAR ATF PLUS (Automatib Transmis-
-ring sion Fluid Type 7176)/Autoniatic trans-
I.D. x Width m m (in.) Identification color
Suction
13A0277
I 1 7 . 8 x 2.4 (.70 x .0945) -
I
19-44 STEERING - Power Steering Oil Pump
10. INSTALLATION OF O-RING/S. O-RING

Apply specified fluid on O-ring to install. -,
Specified fluid: MOPAR ATF PLUS (Automatic Trans- ”
transmission fluid “DEXRONY or “DE-
XRON II”
1 No. 1
I I
I.D. x W idth mm (in.) Identification color
13AO350 21 47.2 16.8 x x 2.4 2.4 (1.86 (.66 x x .0945) .0945) --
8. INSTALLATION OF SIDE PLATE

Align the dowel pin of the pump body with the dowel pin hole
of the side plate to install the side plate.
13PO159
6. INSTALLATlON OF ROTOR
Install the rotor to the pulley assembly so that the rotor’s
Punch mark punch mark is at the pump cover side.
s,
13c214 I

Lift the rotor and check to be sure that the snap ring is in the
countersunk part.
13W03E
4. INSTALLATlON OF VANE/3. CAM RING

(I 1 Apply specified fluid to vane and cam ring friction
surface.
mission Fluid Type 7176)IAutomatic A
Cutouts for “DEXRON II”
dowel pin (21 Align the dowel pins of the pump body with the dowel
holes of the cam ring, and then install so that the cam
13PO161 ring’s punch mark is at the pump body side.
STEERING - Power Steering Oil Pump
(3) Apply specified fluid to the vanes and instafl :lhe yanes
Direct round edge
on the rotor, paying close attention to the installation
,L. , :.I,., ‘,
to the cam ring direction.
mission Fluid Type 7176)/Auto@tic
transmission fluid “DEXFhOW’ or
“DEXRON II”
Cam ring
13R0577
Apply specified fluid to O-ring and install firmly on oil pump
body.
transmission fluid “DEXRON” or “DEd
XRON II”.
1. INSTALLATlON OF PUMP COVER

(1) Apply specified fluid to rotor friction surface of pump
cover.
mission Fluid, Type 7176)/Automatic
“DEXRON II”.
(2) Align the dowel pin of the pump cover with the dowel pin
hole in the cam ring to install the pump cover.
19-46 STEERING - Power Steering Hoses
POWER STEERING HOSES NlSTA-

,‘; ,
L.,.,.
.)
Pre-removal Operation :. ,
l C+?ing of the Power Steering 4-14
wa . . Nm
.-...
I 5-10 ft.lbs.7
9-14 Nm
I I 7 7-10 ft.lbs.
l -.Supplying of the Power Steering
1 Fluid
l Bleeding of the Power Steering
Fluid Line ,621 N/-@b 2
(Refer to P.19-13.1
K
3.0-4.5 Nm /
2-3 ft.lbs. I/II a.
z-”
4 13A0274
Removal steps
1. Return hose 8. Pressure tube
2. Suction hose 9. Return tube
3. Return hose 10. O-ring
4. Cooler tube
5. Return tube NOTE
6. Rubber hose (1) Reverse the removal procedures to reinstall.
.a 7. Pressure hose (2) l a : Refer to “Service Points of Installation”.
NlSTDAD
7. INSTALLATION OF PRESSURE HOSE
(1) Connect the pressure hose so that its slit pat-t contacts
the oil pump’s guide bracket.
(2) When the pressure hose is installed, align the white line
on the pressure hose with the white line on the pressure
tube so that together they form a straight line.
White line
UP0143
TRANSAXLE ’
MANUAL AND AUTOMATIC
CONTENTS
AUTOMATIC TRANSAXLE ..................................................... 137 OUTPUT SHAFT ASSEMBLY.. .................................................................. 61
315 SERVICE ADJUSTMENT PROCEDURES .................................................. ;;
ANNULUS GEAR AND TRANSFER DRIVE GEAR SET (F4A22) ..... .....
ANNULUS GEAR AND TRANSFER DRIVE GEAR SET Drive Shaft Oil Seals Replacement ......................................................
317 Speedometer Cable Replacement ......................................................... ‘li
(F4A33.W4A33) ...........................................................................................
CENTER DIFFERENTIAL (W4A33) ............................................................. 329 Transaxle Oil Level InspectIon ..............................................................
Transaxle Oil Replacement .................................................................... I3
DIFFERENTIAL ............................................................................. ............... 319
END CLUTCH ASSEMBLY ......................................................................... 309 SHIFT LEVER ASSEMBLY ......................................................................... g
EXTENSION HOUSING ASSEMBLY (W4A33) ......................................... 337 SHIFT RAILS AND FORKS ........................................................................
FRONT CLUTCH ASSEMBLY .................................................................... 302 SPECIAL TOOLS ..................... . .................................................. . ................ 1:
FRONT OUTPUT SHAFT (W4A33) ................................................ . .......... 332 SPECIFICATIONS ........................................................................................
GENERAL INFORMATION ......................................................................... 137 General Specifications 5
KICKDOWN SERVO .................................................................................... 322 Lubricants .......................................................................................................................................................................... 10
LOW-REVERSE BRAKE .............................................................................. 323 Sealants and Adhesives 1:
OIL PUMP ................................................................................................... 299 Service Specifications ....................................................................................................................................................
PLANETARY GEAR SET ........................ . .............. . .................................... 311 Snap Ring (for Adjustment) and Spacer ...............................................
Torque Specifications ............................................................................. i
PLANETARY GEAR SET ............................................................................ 313
REAR CLUTCH ASSEMBLY (F4A22) ........................................................ 304 SPEEDOMETER GEAR ASSEMBLY .......................................................... z
REAR CLUTCH ASSEMBLY (FQA33sW4A33) ............................................ 307 TRANS&G.E ........................................... . ....................................................
SERVICE ADJUSTMENT PROCEDURES .................................................. ;;; TRANSAXLE A!jSEMBLY <RM22> ................. . ...................................... i?3
Drive Shaft ,Oil Seals Replacement .................................................... TFlANSAXLE ASSEMBLY <F6M33> ........................................................ g
;- Inhibitor Swtch Adjustment ................................................................ 21 1 TRANSAXLE CONTROL ...................................... . ......................................
Key Interlock Mechanism Check ..................................................... zii TROUBLESHOOTING .................................................................................. 12
Krckdown Servo Adjustment .............................. ..................................
Line Pressure Adjustment ................................................................... 213 MANUAL TRANSAXLE <AWD> ...................................... g
Reducing Pressure Adjustment ........................................... .............. 214 BACKUP LIGHT SWITCH ...........................................................................
Selector Lever Operation Check ........................................................ 210 CENTER DIFFERENTIAL ............................................................................. 103
CLUTCH HOUSING ASSEMBLY ............................................................... ;g
Shift Lock Mechanism Check ............................................................... 21 1
z2: DRIVE BEVEL GEAR ASSEMBLY ..... . . ......................................................
Speedometer Cable Replacement ......................................................... ;g
Throttle-posltipn Sensor Adjustment ................................................. DRIVEN BEVEL GEAR ASSEMBLY ................................... a.. ....................
EXTENSION HOUSING ASSEMBLY .........................................................
Transaxle FluId Level InspectIon ...................................................... 209
101
5Tf.j SPEED SYNCHRONIZER ASSEMBLY ...............................................
Transaxle Fluid Replacement ............................................................. 209
FRONT DlFFERENTlAL ............................................................................... 106
SPECIAL TOOLS .................................... . .................................................... ;“5”9 FRONT OUTPUT SHAFT ASSEMBLY ...................................................... 106
SPECIFICATIONS ........................................................................................ GENERAL I~~~~MATN)N ............................................................... ,., ....... 66
General Speclficatlons .................................................................. 1% INPUT SHAFT ASSEMBLY ........................................................................ ;;i
Lubricants .................................................................................. izi l~ER,“,EDlATE GEAR ASSMBLY ..........................................................
Sealants and Adhesives .............................................................. SERVICE ADJUSTMENT PROCEDURES .................................................. ;;
Serwce Speclflcatlons ............... .................................................. 159 Drive Shaft Oil Seals Replacement ......................................................
Spacer and Snap Ring .,., ............................................................. 1:: Speedometer Cable Replacement ......................................................... ;l
Spacer Set .................................................................. 166 Transaxle Ojl Level lnspectlon .............................................................. 79
T o r q u e Speclflcatlons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transaxle 011 R~pb33ment ....................................................................
Valve Body Spring Identification Chart ..................... ................. 160 80
Transfer Oil Seal Replacement .............................................................
SPEEDOMETER GEAR ASSEMBLY .......................................................... z SHIFT LEVER ASSEMBLY ......................................................................... ,z
TRANSAXLE ASSEMBLY (WA22) ............................................................ SHIFT RAIL ASSEMBLY ............. . .............................................................. 76
TRANSAXLE ASSEMBLY (F4A33.W4A33) ................................................ ;;; 6g
SPECIAL TOOLS .................................. . ......................................................
TRANSAXLE CONTROL ............................................................................. SPECIFICATIONS ........................................................................................ 6g
TRANSAXLE OIL COOLER ........................................................................ fg General Specifications ........................................................................... 75
TRANSFER .................................................................................................. Lubricants ............................................................................................... 76
TRANSFER ASSEMBLY ............................................................................. 333 Sealants and Adhesives ........................................................................ 6g
TRANSFER CASE ADAPTER SUB ASSEMBLY (W4A33) ....................... 339 Service Specifications ............................................................................ 7o
TRANSFER CASE SUB ASSEMBLY (W4A33) 341 Snap Ring (for Adjustment) and Spacer ............................................... 74
TRANSFER SHAFT (F4A33) f;; Torque Specifications .............................................................................
TROUBLESHOOTING ..... .................................... ......................................................................................................................................................... 1:
324 SPEEDOMETER GEAR ASSEMBLY ..........................................................
VALVE BODY ......................... . ................................................................... 86
TRANSAXLE ................................................................................................
MANUAL TRANSAXLE <FWD> ....................................... 2 TRANSAXLE ASSEMBLY ...........................................................................
CLUTCH HOUSING ASSEMBLY ............................................................... E TRANSAXLE CONTROL ...... . ...................................................................... g
DIFFERENTIAL ASSEMBLY ,....._ ................................................................ TRANSFER ............ . .... .._ .............................................................................. ,24
5TH-SPEED SYNCHRONIZER ASSEMBLY ............................................... 42 TRANSFER A!333lBLY .............................................................................
GENERAL INFORMATION ......................................................................... 2 TRANSFER CASE ADAPTER SUB ASSEMBLY ....................................... 131
.-. INPUT fj,-,A,T ASSEMBLY <F5M22> ..................................................... ; TRANSFER CASE SUB ASSEMBLY ......................................................... 1;;
INPUT SHAFT ASSEMBLY <F5M33> ..................................................... TR,,UBLES,,OO,,NG .................. . ...............................................................
INTERMEDIATE GEAR ASSEMBLY .......................................................... 56
21-2 MANUAL TRANSAXLE <FWD> - General Information
MANUAL TRANSAXLE <FWD>

GENERAL INFORMATION NZlBAAP
F5M22 (4637 Engine)
Clutch housing
Bearing retainer
2nd speed gear
3rd soeed aear
5th speed
synchronizer
assemblv
-----..-.I
Rear cover
5th speed inter-

mediate gear
Intermediate gear
Spacer
Output shaft
Spacer
Transaxle case
\Dif ferential drive gear
Spacer
#&---- Drain plug
Diffelential
2060020
MANUAL TRANSAXLE <FWD> - General Information 214
‘. ;
F5M22 (4G63 Engine)
Clutch housing
Bear rinlg retainer
2nd speed gear
1st speed 3rd speed gear

gear
3rd-4th speed synchronizer assembly
1 st-2nd 4th speed gear
speed
synchro- 5th speed gear
nizer
assembly 5th speed
synchronizer
/ assembly
I,
Rear cover
,Reverse gear.
norse-preventron
device
Spacer
Output shaft
Spacer
‘Differential drive gear
Spacer
Drain plug
TFMOOI 1
21-4 MANUAL TRANSAXLE <FWD> - General Information
F5M33
Clutch housing
Bearing retainer 2nd sP teed gear
3rd speed gear

1st speed
- ge’ 3rd-4th speed synchronizer assembly
l--z& ,
Input shaft
I i’ 4th speed gear
I 5th speed gear
1 st-2nd
speed 5th speed
synchro- synchronizer
nizer assembly
assembly /
I
c Rear cover
Reverse gear
noise-prevention
device
Intermediate gear
- Output shaft
‘Differential drive gear
Spacer
/ Drain plug
Differentral
TFMOO25
MANUAL TRANSAXLE <FWD> - Specifications
SPECIFICATIQNS ”
.,
3ENERAL SPECIFICATIONS NZlCA-A
Items T Specifications 1
Model F5M22-1 -VFW F5M22-2-VPZV F5M33-2-SPA!
Applicable engine 4637 4G63-DOHC 4G63-DOHC (Turbo)
Type 5-speed transaxle 5-speed transaxle 5-speed trzinsaxle
floor shift .-
floor shift floor shift ~ ,
Gear ratio
1 st 3.363 3.363 3.090
2nd 1.947 1.947 1.833
3rd 1.285 1.285 1.217
4th 0.939 0.939 0.888
5th 0.756 0.756 0.741
Reverse 3.083 3.083 3.166
Final reduction ratio 4.322 4.322 4.153
Speedometer gear ratio (driven/drive) 29136 29136 29136
Oil quantity liters (qts.) 1.8 (1.9) 1.8 (1.9) 2.2 (2.3)
SERVICE SPECIFICATIONS hl22CBA
Items Specifications mm (in.)
Standard value
Transaxle
Input shaft end play <F5M33> o-0.05 (O-.002)
Input shaft front bearing end play <F5M22> 0.01-0.12 (.0004-.005)
Input shaft rear bearing end play 0.01-0.09 (.0004-.004)
Intermediate gear bearing end play 0.01-0.14 (.0004-,006)
Intermediate gear preload 0.05-0.10 (.002-.004)
Output shaft preload 0.05-0.10 (.002-.004)
Differential
Differential case preload 0.05-0.10 (.002-.004)
Differential pinion backlash 0.025-0.150 LOO1 -.006)
Limit
Synchronizer ring and clutch gear clearance 0.5 (.02)
21-6 MANUAL TRANSAXLE <FWD> - SDecifications
SNAP RING (FOR ADJUSTMENT) AND SPACER

. . .
Part N;: :,‘.I
Part name T h i c k n e s s m m ( i n . ) ‘~y~f$~t’on
Snap ring (F5M22) 2.24 1.0882) None M D706537

(For adjustment of input shaft front bearing 2.31 (.0909) Blue M D706538
end play)
2.38 (.0937) Brown MD706539.f.
Snap ring (F5M22) 1.80 (.0709) Blue MD730785

(For adjustment of input shaft rear bearing 1.87 t.0736) White MD730786
end play)
1.94 t.0764) None MD730787
2.01 (.0791) Green MD730788
2.08 LO81 9) Yellow M D730834
2.15 (.0846) Brown MD730835
Snap ring (F5M33) 1.40 (.0551) Blue MD723276

IFor adjustment ,of input shaft rear bearing 1.45 (.0571) Purple M D730889
and play)
1.50 (.0591) Red MD723277
1.55 (.0610) White M D730890
1.60 (.0630) Yellow MD723278
1.65 (.0650) Brown MD730891
1.70 (.0670) Green MD723279
1.75 f.0689) Orange MD730892
jpacer (F5M33) 0.80 I.031 5) 80 MD727661

For adjustment of input shaft end play) 0.83 (.0327) 83 MD720937
0.86 i.0338) 86 M D720938
0.89 i.0350) 89 MD720939
0.92 t.0362) 92 MD720940
0.95 l.0374) 95 MD720941
0.98 l.0386) 98 MD720942
1 .Ol i.0398) 01 MD720943
1.04 (.0409) 04 MD720944
1.07 (.0421) 07 MD720945
1 .lO (.0433) J MD71 0454
1 .I3 i.0445) D MD700270
1.16 (.0457) K MD71 0455
1.19 (.0468) L MD71 0456
1.22 (.0480) G MD700271
1.25 l.0492) M MD71 0457
1.28 t.0504) N MD71 0458
1.31 f.0516) E MD706574
1.34 (.0527) 0 MD710459
1.37 (.0539) P MD710460
1.40 (.0551) - MD706573
1.43 i.0563) Q MD710461
1.46 t.0575) R M D7 10462
nap ring 1 . 4 (.0551) None MD703779
‘or adjustment of intermediate gear front bearing
1.5 (.0591) Brown MD703780
nd play)
1.6 (0630) Blue MD703781
MANUAL TRANSAXLE <Fwb - Specifications ,nj-r
.
Part name T h i c k n e s s m m ( i n . ) ~ye~~~~tion Part No.
Spacer (F5M22) 0.68 t.0268) 68 MD735663 ’

(For adjustment of intermediate gear preload)
0.71 (.0280) 71 MD735664
0.74 (.0291) 74 MD735665
0.77 (.0303) 77 MD735666
0.80 LO31 5) 80 M D723307
0.83 f.0327) 83 M D723308
0.86 i.0338) 86 MD723309
0.89 i.0350) 89 MD72331 0
0.92 i.0362) 92 MD72331 1
0.95 (.0374) 95 MD72331 2
0.98 i.0394) 98 MD72331 3
1 .Ol (.0398) 01 MD723314
1.04 (.0409) 04 MD72331 5
1.07 (.0421) 07 MD72331 6
1 .I0 (.0433) 10 MD72331 7
1.13 (.0445) 13 MD72331 8
1 .16 i.0457) 16 MD72331 9
1.19 (.0468) 19 MD723320
1.22 (.0480) 22 MD723321
1.25 t.0492) 25 M D723322
1.28 (.0504) 28 MD723323
1.31 (.0516) 31 MD723324
1.34 (.0527) 34 MD723325
1.37 (.0539) 37 M D723326
Spacer (F5M33) 0.80 LO31 5) 80 MD7241 42

:For adjustment o f intermediate gear preload) 0.83 (.0327) 83 MD7241 43
0.86 t.0338) 86 MD7241 44
0.89 (.0350) 89 MD7241 45
0.92 (.0362) 92 MD7241 46
0.95 f.0374) 95 MD7241 47
0.98 i.0386) 98 MD7241 48
1 .Ol (.0398) 01 MD7241 49
1.04 (.0409) 04 MD7241 50
1.07 i.0421) 07 MD7241 51
1.10 l.0433) 10 MD7241 52
1 .I3 i.0445) 13 MD7241 53
1.16 (.0457) 16 MD7241 54
1.19 l.0468) 19 MD7241 55
1.22 i.0480) 22 MD7241 56
1.25 (.0492) 25 MD7241 57
1.28 (.0504) 28 MD7241 58
1.31 LO51 6) 31 MD7241 59
1.34 (.0527) 34 MD7241 60
1.37 i.0539) 37 MD7241 61
ipacer 0.83 (.0327) 83 MD720949

=or adjustment of output shaft preload) 0.86 i.0338) 86 M D720950
0.89 i.0350) 89 MD720951
21-8 MANUAL TRANSAXLE <FWD> - Specifications
Part name T h i c k n e s s m m ( i n . ) ~dyemnt$j~at'on Part No.
Spacer 0.92 (0362) 92 MD720952

(For adjustment of output shaft preload) 0.95 (0374) 95 MD720953
0.98 (.0386) 98 MD720954
1 .Ol t.0398) 01 MD720955
1.04 (.0409) 04 MD720956
1.07 (.0421) 07 MD720957
1.10 (0433) 10 MD720958
1 .I3 (0445) 13 MD720959
1 .16 (0457) 16 MD720960
1 .I9 (0468) 19 M D720961
1.22 (.0480) 22 MD720962
1.25 (.0492) 25 MD712346
1.28 (0504) 28 MD71 2347
1.31 (0516) 31 M D7 12348
1.34 (.0527) 34 MD71 2349
spacer (F5M33) 0.83 (0327) 83 MD720937

For adjustment of output shaft preload) 0.86 (0338) 86 M D720938
0.89 (0350) 89 MD720939
0.92 (0362) 92 MD720940
0.95 (.0374) 95 MD720941
0.98 (0386) 98 MD720942
1 .Ol l.0398) 01 MD720943
1.04 (.0409) 04 M D720944
1.07 (0421) 07 MD720945
1 . 10 (.0433) J MD710454
1 .I3 (0445) D MD700270
1.16 (.0457) K MD71 0455
1 .I9 (0468) L MD710456
1.22 (.0480) G MD700271
1.25 (.0492) M MD710457
1.28 (.0504) N MD710458
1.31 (.0516) E MD706574
1.34 (.0527) 0 MD710459
ipacer 0.80 (.0315) 80 MD727661

'or adjustment of differential case preload) 0.83 (.0327) 83 MD720937
0.86 (.0338) 86 MD720938
0.89 (0350) 89 MD720939
0.92 (.0362) 92 M D720940
0.95 (.0374) 95 MD720941
0.98 (.0394) 98 MD720942
1 .Ol t.0398) 01 MD720943
1.04 i.0409) 04 MD720944
1.07 (.0421) 07 MD720945
1 .I0 (0433) J MD71 0454
1 .I3 (0445) D MD700270
1 .I 6 (.0457) K MD710455
1 .19 (0468) L MD710456
Part name Identification

Thickness mm (in.) P a r t N o .
symbol
Spacer 1.22 f.0480) G

(For adjustment of differential case preload) 1.25 (.0492) M
Spacer 0.75-0.82 MA180862

(For adjustment of differential pinion backlash) (.0295-.0323)
0.83-0.92 -
(.0327-.0362)
0.93- 1 .oo - MA1 80866
(.0366-.0394)
1.01-1.08 - MA1 80875
(.0398-.0425)
1.09-1.16 - MA1 86876
(.0429-.0457)
Items Nm ft.lbs.
Shift lever to lever (A) 19-28 13-20

Lever (A) to bracket assembly 17-26 12-18
Filler plug 30-35 22-25
Starter motor mounting bolt 27-34 20-25
Transaxle bracket 60-80 43-58
Shift lever knob 4.5-7.5 3-5
Shift cable and select cable to body 9-14 7-10
Shift lever assembly to body 9-14 7-10
Automatic seat belt guide ring attaching bolt 17-26 12-19
Clutch release cylinder mounting bolt 15-22 11-16
Clutch tube to transaxle assembly 15-22 11-16
Transaxle mount bracket to transaxle 60-80 43-58
Shift cable and select cable to transaxle 15-22 11-16
Under cover 9-13 7-10
Transaxle mounting bolt [12 mm (.47 in.) diameter bolt1 43-55 32-39
Transaxle mounting bolt [IO mm (.40 in.) diameter bolt1 30-35 22-25
Transaxle mounting bolt [8 mm (.31 in.) diameter bolt] IO-12 7-9
Lower arm ball joint to knuckle 60-72 43-52
Bell housing cover IO-12 7-9
3ear cover bolt 15-22 11-15
3ackup light switch 30-35 22-25
loppet plug 30-42 22-30
jpeedometer sleeve bolt 3.0-5.0 2.5-3.5
nput shaft lock nut 140-160 102-I 15
n t e r m e d i a tgear
e lock nut 140-160 102-115
3everse idler gear shaft bolt 43-55 32-39
rransaxle case tightening bolt 35-42 26-30
stopper bracket bolt 15-22 11-15
qestrict ball assembly 30-35 22-25
Items Nm ftlbs.
Reverse shift lever assembly attaching bolt 15-22 11-15

Bearing retainer bolt 15-22 11-15
Differential drive gear bolt 130-140 94-101
Interlock plate bolt 20-27 15-19
Select lever assembly mounting bolt 15-22 11-15
LUBRICANTS NZlCD-A
Items Specified lubricant Quantity lit. (qts.)
Manual transaxle oil MOPAR Hypoid gear oil or equivalent <F5M22> 1.8 (1.9)
API classification GL-4 or higher <F5M33> 2 . 2 ( 2 . 3 ) ’
Drive shaft oil seal lip MOPAR Hypoid gear oil or equivalent As required
API classification GL-4 or higher
Shift lever bushing MOPAR Front Wheel Bearing Grease As required

SEALANTS AND ADHESIVES NZlCE-A
I Items Specified sealants and adhesives I
Transaxle case-clutch housing mating surfaces Mitsubishi genuine Part No. MD997740 or equivalent
Transaxle case-rear cover mating surfaces
Differential drive gear bolts MOPAR Part No.4318031 or MOPAR Part No.4318032
Bearing retainer screw (flush head screw) or equivalent
I
Air breather MOPAR Part No.4318025 or equivalent

MANUAL TRANSAXLE <FWD> - Special Tools ’ 2149
”
SPECIAL TOOLS N?/bA-A
21-12 M A N U A L T R A N S A X L E <FWD> - Special Tools/Troubleshooting
I IICP
intermediate shaft lock nut
MD998819 Installer adapter Installation of differential case bearing
TROUBLESHOOTING NZlEAABs
Vibration, noise a. Loose or damaged transaxle and a. Tighten or replace mounts

engine mounts
b. Inadequate shaft end play b. Correct end play
c. Worn of damaged gears c. Replace gears
d. Use of inadequate grade of oil d. Replace with specified oil
e. Low oil level e. Replenish
f. Inadequate engine idle speed f. Adjust idle speed
3il leakage a. Broken or damaged, oil seal or O-ring a. Replace oil seal or O-ring
Hard shift a. Faulty control cable a. Replace control cable
b. Poor contact or wear of synchronizer ring b. Correct or replace

and gear cone
c. Weakened synchronizer spring c. Replace synchronizer spring
d. Use of inadequate grade of oil d. Replace with specified oil
Jumps out of gear a. Worn gear shift fork or broken poppet a. Replace shift fork or poppet spring
spring
b. Synchronizer hub to sleeve spline clear- b. Replace synchronizer hub and sleeve
ante too large
MANUAL TRANSAXLE <FWD> - Service Adjustment Procedures 21-13
N21FBABl
TRANSAXLE OIL LEVEL INSPECTION

Refer to GROUP O-Maintenance Service.
TRANSAXLE OIL REPLACEMENT NZlFCADa
(1) Position vehicle on a flat level.

(2) Remove filler and drain plugs and allow the transaxle oil to
drain.
(3) Refill the transaxle to the proper level with specified
transaxle oil. The oil level should be the bottom of the oil
filler hole.
Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification GL-4 or hiqher
<F5M22> 1.8 liters (1.9 qts.)
<F5M33> 2.2 liters ‘(2.3 qts.)
00”0110 09FOli ,
DRIVE SHAFT OIL SEALS REPLACEMENT NZlFDACa
I (1) Disconnect the drive shaft from the transaxle.

I (Refer to GROUP 2-Drive Shaft.)
(2) Using a flat-tip (-) screwdriver, remove the oil seal.
I I 09K56i
;
‘:,
\;
\
\
I
09K56f
(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
(4) Apply a coating of the transaxle oil to the lip of the oil seal.
Transaxle oil: MOPAR Hypoid gear oil or equivalent
21-14 M A N U A L T R A N S A X L E <FWD> - Service Adjustment Procedures
SPEEDOMETER CABLE REPLACEMENT NZlFEAKl
1. Correctly insert the adapter into the instrument panel, and S.

fasten the new speedometer cable. 1-
I- Adapter %A0905
2. Install the grommet so that, as shown in the illustration, the

cable attachment is positioned upward.
Caution
1. The cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
2. The arrangement of the speedometer cable should
be such that it does not interfere with other parts.
3. At the transaxle end of the speedometer cable, the key

joint should be inserted into the transaxle, and the nut
should be securely tightened.
Caution lllc
If the cable is not correctly and securely connected, it
may cause incorrect indication by the speedometer, or
abnormal noise. Be sure to connect it correctly.
MANUAL TRANSAXLE <FWD> - Transaxle Control 2M5
TRANSAXLE CONTROL
-^ REMOVAL AND INSTALLATION N21JA-A
19AO349
9
9-14 Nm .
9-14 N m
7- 10 ftlbs.
+-
0
0 OQA0174
Removal steps
1. Plug 12. Cotter pin
2. Side cover (A) 13. Retainer
3. Side cover(B) 14. Retainer
4. Cover(B) 15. Cotter pin
5. Manual transaxle shift lever knob I)4 16. Shift cable
6. Cup holder I)+ 17. Select cable
7. Carpet 18. Shift lever assembly
8. Connection for floor console wiring
harness NOTE
9. Guide ring (1) Reverse the removal procedures to reinstall.
10. Shoulder belt (2) *a : Refer to “Service Points of Installation”.
11. Floor console (3) m : Non-reusable parts
21-16 MANUAL TRANSAXLE <FWD> - Transaxle Control
INSPECTION N21JcAD
l Check the select cable for funct,ion and for damage. k

,I
l Check the shift cable for function and for damage. .,
,
l Check the boot for damage.
l Check each bushing for wear or abrasion, sticking,
impeded action, and damage.
l Check the spring for deteriorated strength.
SERVICE POINTS OF INSTALLATION NZlJDAK
17. INSTALLATION OF SELECT CABLE

(1) Move the transaxle shift lever to the neutral position.
NOTE
The select lever will be set to the neutral position when
the transaxle shift lever is moved to the neutral
position.
(2) Move lever (6) to the neutral position.
I CBA0160 1
I (3) Adjust, by using the adjuster, so that the end of the

Incorrect 5 ,I select cable is positioned as shown in the illustration
-ri relative to lever (B).
I
I
Incorrect 1, ,,1 :
-I I
(4) The flange side of the resin bushing at the select cable
end should be at the lever (B) end surface.
Sele’ct A .
cable
Flange side y
of the resin L
bushing
Lever & OSAOl72

MANUAL TRANSAXLE <FWD> - Transaxle Contid
16. INSTALLATION OF SHIFT CABLE
(1) With the select lever in neutral, move the transaxle shift
lever (in the direction shown in the illustration) to set it
to 4th gear.
NOTE
If the shift lever does not move easily, depress and hold
er the clutch pedal.
(2) Move the shift lever (at the vehicle interior side)
downward, in the direction (4th gear position) shown in
the illustration until it contacts the stopper.
(3) Adjust, by using the adjuster, so that the end of the shift
cable is positioned as shown in the illustration relative
Shift
lever to the shift lever (interior side).
(4) The flange side of the resin bushing at the shift cable
end should be at the split pin side.
09A0159
(5) Adjust the length of the shift cable, by using the

adjuster, so that the clearance (A) and (B) between the
shift lever and the two stoppers are equal when the
shift lever is shifted to 3rd gear and 4th gear.
(6) Move the shift lever to each position and check that the
shifting is smooth.
09A016t
21-18 MANUAL TRANSAXLE <FWD> - Shift Lever Assembly
SHIFT LEVER ASSEMBLY

19-28 Nm
14-20 ft.lbs.
Disassembly steps
1. Shift lever 17-26
e+ 2. Bushing i%s.
*q~ 3. Return spring
1)4 4. Bushing
5. Lever (A)
*4 7. ;;;;;w
I)+ 8: Bushing
9. Snap ring
10. Lever (B) 09A0173
.+ 11. Bushing
12. Bracket assembly
NOTE
(3) •J : Non-reusable parts.
SERVICE POINTS OF REASSEMBLY NZlGHAP
11./8./6./4,/3./2. APPLICATION OF GREASE TO

BUSHINGS
Apply multi-purpose grease to the sliding part of the
bushings shown in the figure.
Grease: MOPAR Front Wheel Bearing
Grease Part No.3837794 or equivalent
3. INSTALLATION OF RETURN SPRING

Make sure that the end of the spring contacts the part
(shown in the illustration) of the bracket.
MANUAL TRANSAXLE <FWD> - Transaxle 21-19
TRANSAXLE
- REMOVAL AND INSTALLATION NZlMA-A
27-34 N m
20-25 ft.lbs.
60-80 Nm*
15-22 Nm 43-58 ft.lbs.* 60-80 Nm
11-16 ft.lbs.
/ da-,, ft.lbs.
43-55 N m
32-39 ft.lbs.
lo-12 Nm I
7-9 ft.lbs. I
..
15-2: Nm OOAOl~4
11-16 ft.lbs.
rPre-removal Operation
@Removal of the Battery
l Draining of the Transaxle Oil (Refer to P.21-13.)
l Removal of the Air Hose
(Refer to GROUP 11-Air Cleaner.)
Post-installation 0 eration
l installation of the I!attery
l supplying of Transaxle Oil (Refer to P.21-13.)
*Installation of the Air Hose
(Refer to GROUP 11 -Air Cleaner.)
l checking the Operation of the Shift Lever
l checkina the Ooeration of the Meters and Gauges
Removal steps
1. Cotter pin ZKeverse the removal procedures to reinstall. ” ’
2. Connection for select cable (2) W : Refer to “Service Points of Removal”.
3. Connection for shift cable (3) ~~ : Refer to “Service Points of Installation”.
4* 4. Connection for clutch release cylinder (4) m : Non-reusable parts
5. Backup light switch connector (5) For tightening locations indicated by the * symbol, fjrst
6. Connection for speedometer cable tighten temporarily, and then make the final tightenrng
,- I)* 7. Starter with the entire weight of the engine applied to the
8. Lfrsaxle assembly upper part coupling vehicle body.
(6) If the rease has been wiped from the input shaft spline
9. Transaxle mount bracket or if tae input shaft has been replaced, apply specral
grease (MOPAR Multi-mileage Lubricant Part
No.2525035 or equivalent) to the input shaft Spline.
21-20 MANUAL TRANSAXLE <FWD> - Transaxle
9-13 Nm
7-10 ftlbs.
I
30-35 Nm
IO-12 Nm Ld
7-9 ft.lbs.
60-72 Nm
,!24-35 Nm
17-25 ft.lbs.
+I) IO. Under cover

11. Cotter pin
+I) 12. Connection for tie rod end
** 14. Connection for lower arm ball joint
+I) l I 15. Connection for drive shaft
16. Circlip
18. iT,nsaxle assembly lower part coupling
W e+ 19. Transaxle assembly
NOTE
(2) +e: Refer to “Service Points of Removal”.
(3) ~~ : Refer to “Service Points of Installation”.
MANUAL TRANSAXLE <FWD> - Transaxle’
SERVICE POINTS OF REMOVAL NlZMBAR
--- 4. DISCONNECTION OF CLUTCH ‘RELEASE CYLINDER

F R O M T R A N S A XLE A S S EM BL Y
Remove the clutch release cylinder and clutch oil line

bracket installation bolt, and then secure at the ! body side
without disconnecting the oil line coupling. ”
10. REMOVAL OF UNDER COVER
Lift the vehicle before removing the under cover.
12. DISCONNECTION OF TIE ROD END FROM KNUCKLE

knuckle.
Caution
nearby part.

from the knuckle.
-.. Caution
nearby part. I
15. DISCONNECTION OF DRIVE SHAFT

(1) Insert a pry bar between the transaxle case and the
drive shaft, and then pry the drive shaft ~from the
transaxle.
Caution
damage the inboard joint; be sure to use the pry
bar.
2) ’ 2. Do not insert the pry bar so deep as to damaged
Transaxle the oil seal.
llK611
(2) Keep the removed drive shaft as far away from the
transaxle case as possible, and secure (by using rope,
etc.) the joints to the body so that it does not fall.
21-22 MANUAL TRANSAXLE <FM/D> - Transaxle
1 Transaxle side 1 Radiator lower hose 19. REMOVAL OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging +G
the lower hose of the radiator with the end of the ’
transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
Support the transaxle assembly by using a transaxle jack;

then, after moving the transaxle assembly to the right,
lower it.
NOTE
When supporting the transaxle assembly by the transaxle
jack, take care to be sure that the jack’s force is applied to a
wide area, not to only a small localized area.
1 Transaxle side 1 Radiator lower hose SERVICE POINTS OF INSTALLATION NZlMDAP
19. INSTALLATION OF TRANSAXLE ASSEMBLY

Caution
On the turbo vehicle, take care to prevent damaging A
the lower hose of the radiator with the end of the -
transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
15. INSTALLATION OF DRIVE SHAFT

(1) Provisionally install the drive shaft so that the inboard
joint part of the drive shaft is straight, and not bent
relative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip
part of the transaxle is not damaged by the serrated
part of the drive shaft.
part of drive shaft I -
Transaxle (2) Align the serrations and securely insert the drive shaft
09LOO58
into the transaxle.
7. INSTALLATION OF STARTER
Tighten the starter installation bolts with the wiring harness
clip and the ground cable.
MANUAL TRANSAXLE <FWD> - Transaxle Assemblv <F5M22’> 2743
TRANSAXLE ASSEMBLY <F5M22>
._ DISASSEMBLY AND REASSEMBLY N21ME-A
15-22 Nm
II-15 ft.lbs.
30-42 Nm 30-35 Nm 4.0-5.5 Nm
a
22-30 ft.lbs. 22-25 ftlbs. q l4
IQ
2.9-3.9 ft.lbs. 1
I” I
140-160 Nm f
ig5 ! 102-115 ft.lbs.
----7m
140-160
102-115
TFMOOl6
Disassembly steps
1. Bolt
l + 2. Rear cover +e I)+ 16. Lock nut
3. Wave spring 17. 5th speed synchronizer assembly
l 4. Screw bolts <F5M22-2> 18. 5th speed shift fork
5. Reverse brake cone 19. Synchronizer ring
6. Backup light switch 20. 5th speed gear
7. Gasket 21. Needle bearing
8. Poppet plug 22. 5th speed intermediate gear
9. Poppet spring
10. Poppet ball
__ 11. Bolt NOTE
12. Speedometer driven gear assembly (1) Reverse the disassembly procedures to reasseinble.
l * 13. Air breather (2) ++ : Refer to “Service Points of Disassembly”.
*I) l * 14. Spring pin (3) l * : Refer to “Service Points of ReaSsembly”:
+I) l * 15. Lock nut (4) m : Non-reusable parts
21-24 MANUAL TRANSAXLE <FWD> - Transaxle Assemblv <F5M22>
3e42 Nm
48 22-30 ft.lbs.
30-35 Nm I
12 2-25 ft.lbs.
26 25
27
1!&22 Nm
\
Disassembly steps
23. Reverse idler gear shaft bolt l + 39. Spacer
24. Gasket 40. Bolt
25. Bolt 41. Reverse shift lever assembly
++ 26. Transaxle case 42. Reverse shift lever shoe
l + 27. Oil guide 43. Reverse idler gear shaft
28. Bolt 44. Reverse idler gear
29. Spring washer +I) l 4 45. Spring pin
30. Stopper bracket ~~ ~~ 46. Spring pin
31. Restrict ball assembly +* l + 47. Shift rails and forks
32. Gasket +* l 48. Shift rails and forks
l 4 33. Oil seal
34. Bearing outer race
NOTE
+* 35. Spacer (1) Reverse the disassembly procedures to reassemble.
36. Bearing outer race (2) +* : Refer to “Service Points of Disassembly”.
l * 37. Spacer (3) l * : Refer to “Service Points of Reassembly”y
38. Bearing outer race (4) m : Non-reusable parts
2i &
MANUAL TRANSAXLE <FWD> - Transaxle Assembly <F5M22>
15-22 Nm
50 11-15 ft.lbs.
Disassembly steps
l +49. Bolt l 4 60. Oil seal
50. Screw W 61. Oil seal
51. Bearing retainer 62. Magnet
+e l + 52. Intermediate gear assembly 63. Magnet holder
l + 53. Input shaft assembly 64. Clutch housing assembly
54. Output shaft assembly
55. Differential gear assembly NOTE
56. Bearing outer race (1) Reverse the disassembly procedures to reassemble.
57. Oil guide (2) ~~ : Refer to “Service Points of Disassembly”.
58. Bearing outer race (3) e+ : Refer to “Service Points of Reassembly”.
21421
21-26 MANUAL TRANSAXLE <FWD> - Transaxle Assembly <F5M22>
SERVICE POINTS OF DISASSEMBLY NZlMFAR
I MD99801 9
\ I 14. REMOVAL OF SPRING PIN
Remove the spring pin using the special tool.
15.116. REMOVAL OF LOCK NUTS

(1) Unstake lock nuts of the input shaft and intermediate
gear.
(2) Shift the transmission in reverse using the control lever

and select lever.
Bolt (3) install the special tool onto the input shaft.
10 mm (4) Screw a bolt [IO mm] into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.
45./46. REMOVAL OF SPRING PINS

Remove the spring pins for 1 st-2nd and 3rd-4th speed shift
forks using the pin punch.
MANUAL TRANSAXLE <FWD> - Transaxle Assemblv <F5M22> 21-27
47./48. REMOVAL OF SHIFT RAILS AND FORKS’
(1) Shift the Ist-2nd speed shift fork to the 2nd speed.
(2) Shift the 3rd~4th speed shift fork to the 4th speed.
(3) Rotate the the shift controls in the direction of the arrow
in numerical order. Remove the shift lugs from the
control finger and interlock plate.
(4) Raise each of the shift rails upward and remove them
from the clutch housing.
(5) Remove the all shift rails and forks.
52. REMOVAL OF INTERMEDIATE GEAR ASSEMBLY

Lift up the input shaft assembly and remove the intermedi-
ate gear assembly.
INSPECTION N21MOd
BACKUP LIGHT SWITCH

Operate the backup light switch to check continuity with a
circuit tester. If without continuity, replace the switch.
206001E
SERVICE POINTS OF REASSEMBLY N2mnGAU

Install the drive shaft oil seal using the special tool.
21-28 MANUAL TRANSAXLE <FWD> - Transaxle Assemblv <F5M22>
seal
201025

Install the input shaft front oil seal using the special tool.
52. INSTALLATION OF INTERMEDIATE GEAR ASSEMBLY /

53. INPUT SHAFT ASSEMBLY
Lifting up the input shaft assembly, install it simultaneously
with the intermediate gear assembly.
49. APPLICATION OF ADHESIVE TO BOLT

Apply adhesive Apply specified adhesive to the bolt threads.
Caution
Do not apply to the bolt head.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No.4318032
or equivalent
(.2 in.)
TFMOO63
MANUAL TRANSAXLE <FWD> - Transaxle Asshmblv <F5M22> 21-23
47./48. INSTALLATION OF SHIFT RAILS AND FORKS
(1) Set the lst-2nd speed shift sleeve at 2nd Speed.
(2) Set the 3rd-4th speed shift sleeve at 4th spe$d.
(3) Fit the shift forks of shift rail assembly to groove of
sleeves.
(4) Insert the shift rails into the shift rail holes of clutch
housing.
(5) Turn the shift rails in the directions indicated by the
arrows in the order shown in the illustration, and
engage the shift lugs to control finger and interlock
plate.
45.146. INSTALLATION OF SPRING PINS

Install the spring pins using the special tool or a pin Punch.
When installing, make sure that the slit of the spring pin is
aligned with the shift rail center line.
Caution
Do not reuse the spring pins.
35.137.139. SELECTION OF SPACERS

(1) Place two pieces of solder measuring about Ia mm (.4
in.) in length and 1.6 mm (.06 in.) in diameter as
illustrated and install the outer races of intermediate
gear and differential.
(2) With a solder puddle measuring 10 mm (.39 in.) long

and 1.6 mm (.06 in.) across on the transaxle case at the
location shown in the figure, install the bearing outer
race of the shaft.
(3) Install the transaxle case and tighten the bolts to
specified torque.
(4) Remove the transaxle case.
(5) Remove the outer races and take out the crushed
solder.
(6) If the solder is not broken, carry out the work in steps
TFM0006 (l)-(5) with large diameter solder.
(7) Measure the thickness of the crushed solder with a
micrometer and select a spacer of thickness that gives
standard preload. ,&
Standard value:
Intermediate shaft
0.05-0.10 mm (.002-,004 in.)
Output shaft
0.05-0.10 mm (.002-.004 in.)
Differential case
0.05-0.10 mm (.002-,004 in.)
2200048

27. INSTALLATION OF OIL GUIDE

Install the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE

(1) Place the selected spacers on the intermediate gear
and the differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outer
race and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gear
shaft’s head is facing in the direction indicated in the
illustration.
NOTE
If there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align the
threaded hole and the hole in the case after the
transaxle case is installed.
I Amount l-2 mm (3) Apply specified sealant to the clutch housing side of the
transaxle case.
Specified sealant: MITSUBISHI Genuine
Part No.MD997740 or
equivalent
B
Caution
Squeeze out sealant from the tube uniformly with- -
out excess or discontinuity.
(4) Install the transaxle case onto the clutch housing.
MANUAL TRANSAXLE <WD> - Transaxle Assembly <F5M22> 2%3T
(5) Insert a Phillips screwdriver [8 mm (.32 in.) shaft

diameter] into the bolt hole in the case, as shown in the
figure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten the
bolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
(8) E$r& the reverse idle gear shaft bolt to specified

torque.
15./ 16. INSTALLATION OF LOCK NUTS

(1) Install the special tool to the splined end of input shaft.
(2) Screw a bolt (10 mm) into the hole on the periphery of
special tool.
(3) Shift the transmission in reverse using control lever and

select lever.
(4) Tighten the lock nut,to specified torque, while ‘using the
bolt attached in the above step as a spinner handle
stopper.
(5) Loosen the lock nuts.
(6) Retighten the lock nuts to the specified torque.
(7) Stake the lock nut.
14. INSTALLATION OF SPRING PIN

I MD998245
(1) Install the spring pin using the special tool or a pin
punch.
Caution
(2) When installing, make sure that the slit of the spring pin
Slit is aligned with the shift rail center line.
fi
201034
13. APPLICATION OF SEALANT TO AIR BREATHER

Apply specified sealant to air breather mounting portion and
install to the clutch housing.
or equivalent
2010043
4. INSTALLATION OF SCREW BOLTS

Apply specified adhesive to screw bolts mounting portion.
APPLY a
Specified adhesive: 3M Stud Locking No.4170 -
TFM0041
2. APPLICATION OF SEALANT TO REAR COVER

Apply specified sealant to the rear cover.
Specified sealant: MITSUBISHI Genuine Part
No. MD997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly wlthout
excess or discontinuity.
TFM0044
MANUAL TRANSAXLE <FWD> - Transaxle Assembly <F5M33> n-33
TRANSAXLE ASSEMBLY <F5M33>
3 DISASSEMBLY AND REASSEMBLY NZlME-6
16-22 Nm
11-15 ft.lbs.
1
-42 Nm 30-35 Nm 4.0-5.5 Nm
- 3 0 ft.lbs. 22-25 ft.lbs. ml4 18 2.9-3.9 ft.lbs. ,I
-n
8
\ I Q 140-160 Nm
ff3d6 i 102-115 ft.&s.
3-5 Nm
TFMool6
Disassembly steps
‘I. Bolt 4+ e4 15. Lock nut
l * 2. Rear cover +e l 16. Lock nut
3. Wave spring 17. 5th speed synchronizer assembly
e4 4. Screw bolts 18. 5th speed shift fork
5. Reverse brake cone 19. Synchronizer ring
6. Backup light switch 20. 5th speed gear
7. Gasket 21. Needle bearing
8. Poppet plug 22. 5th speed intermediate gear .’
- 9. Poppert spring
10. Poppet ball
11. Bolt $?everse the disassembly procedures to reassemble.
12. Speedometer driven gear assembly (2) +e : Refer to “Service Points of Disassembly:.
l 13. Air breather (3) l C : Refer to “Service Points of Reassembly
4* l * 14. Spring pin (4) q : Non-reusable parts
? ,‘,
30-35 Nm 35-42 Nni

77-25 fLlbs. 26-30 ftlbs.
25
--2lRl 2 6
APi 7 7
23
\ \15-22
- - -- -_Nm
..
II-15 lt.lDS.
..d.. -
32-39 ft.lbs.
TFMOlO9
Disassembly steps l 4 40. Spacer

23. Reverse idler gear shaft bolt 41. Bearing outer race
24. Gasket I)* ;I. Sggcer
25. Bolt
l + 26. Transaxle case 44: Reverse shift lever assembly
+4 ;I. ;$yrde 45. Reverse shift lever shoe
l + 46. Reverse idler gear shaft
29: Spring washer 47. Reverse idler gear
30. Stopper bracket +e l + 48. Spring pin
31. Restrict ball assembly l * l + 49. Spring pin
32. Gasket +I) l 50. Shift rail assembly
l 4 33. Oil seal
l * 35. Spacer NOTE
36. Bearing outer race (I) Reverse the disassembly procedures to reassemble.
l 4 37. Spacer (2) +e : Refer to “Service Points of Disassembly”.
38. Oil filter (3) e* : Refer to “Service Points of Reassembly”.
39. Bearing outer race (4) 19 : Non-reusable parts
MANUAL TRANSAXLE <FWD> - Transaxle Assembly <F5M33>
2%35
11-15 ftlbs.
51
15-22 Nm
11-15 ftlbs.
/’
62
; .,
l,451. Bolt +4 63. Oil seal
52. Bolt +4 64. Oil seal
53. Bearing retainer 65. Magnet
54. Intermediate gear assembly 66. Magnet holder
55. Input shaft assembly 67. Clutch housing assembly
56. Output shaft assembly
_- 57. Differential gear assembly
60. Oil guide FFkeverse the disassembly procedures to rdassembte.
61. Bearing outer race (2) ++ : Refer to “Service Points of Reassem’bly”.
SERVICE POINTS OF DISASSEMBLY NZlMFAS
I MD99801 9 I
14. REMOVAL OF SPRING PIN
Remove the spring pin using a special tool.
NOTE
If the spring pin interferes with the synchronizer ring or
cone gear, rotate the gear for dislocation and remove the
spring pin.
15. / 16. REMOVAL OF LOCK NUTS

gear.
(2) Shift the transaxle in reverse using the control lever and
select lever.
(3) Install the special tool onto the input shaft.

(4) Screw a bolt [IO mm] into the hole on the periphery of
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.
48.149. REMOVAL OF SPRING PINS

Remove the spring pins for 1 st-2nd and 3rd-4th speed shift
forks using a pin punch.
MANUAL TRANSAXLE <FWD> - Transaxle Assemblv <F5M33> 21-37
50. REMOVAL OF SHIFT RAIL ASSEMBLY
(1) Shift the 1st~2nd speed shift fork to the 2nd speed.
(2) Shift the 3rd4th speed shift fork to the 4th speed.
.”
(3) Remove the shift rail assembly.
NZlMOM
INSPECTION
BACKUP LIGHT SWITCH
Operate the backup light switch to check continuity with a
circuit tester.
If without continuity, replace the switch.

:
18

Install the input shaft front oil seal using the special tool. ,,=
2010041
51. APPLICATION OF ADHESIVE TO BOLT

Apply specified adhesive to the bolt threads.
Caution
Do not apply to the bolt head.
or equivalent
50. INSTALLATION OF SHIFT RAIL ASSEMBLY

(1) Set the lst-2nd speed shift sleeve at 2nd speed.
(2) Set the 3rd-4th speed shift sleeve at 4th speed.
(3) FJtt~~~shift forks of shift rail assembly to groove of
(4) Insert the shift rails into the shift rail holes of clutch
housing.
plate. A
MANUAL TRANSAXLE <FWD> - Transaxle Assembly <F5M335 21 A&
46./49. INSTALLATION OF SPRING PINS

(1) Install the spring pins using the special tool or a pin
punch.
Caution
(2) When installing, make sure that the slit of the spring pin
Slit
is aligned with the shift rail center line.
Spring pin
11-t
/Shift rail
201034
46. INSTALLATION OF REVERSE IDLER GEAR SHAFT

Install in the direction illustrated. ’
35. /37. /40./42. INSTALLATION OF SPACERS

er (1) Place two pieces of solder measuring about 10 mm (4
in.) in length and 1.6 mm (.06 in.) in diameter as
illustrated and install the outer races. ’
(2) Install the transaxle case and tighten the bolts to
specified torque.
(4) Remove the outer races and remove the solder.
(5) If the solder is not broken, carry out the work- in steps
(l)-(4) with large diameter solder.
2150008
(6) Measure the thickness of the crushed soid& with a
micrometer and select and install a spacer of thickness
that gives standard preload and end play.
Standard value:
Input shaft end play
O-0.05 mm (O-.002 in.)
Intermediate gear preload
0.05-0.10 mm (.002-.004 in.)
Output shaft preload
0.05-0.10 mm (.092-.004 in.)
Differential case preload
220004E 9.05-0.10 mm (.002-.004 in.)

Install the drive shaft oil seal using the special tool. .‘p,
/
27. INSTALLATION OF OIL GUIDE

Install the oil guide to the transaxle case as illustrated.

(1) Place the selected spacers on the intermediate gear
and the differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outer
race and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gear h
shaft’s head is facing in the direction indicated in the .-
illustration.
NOTE
If there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align the
threaded hole and the hole in the case after the
J transaxle case is installed.
Amount 1-2 mm (3) Apply specified sealant to the clutch housing side of the
transaxle case.
Part No. MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.
(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver 18 mm (32 in.) shaft
diameter] into the bolt hole in the case, as shown in the
figure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten the
bolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified *
torque. ,-
(8) Tighten the reverse idler gear shaft bolt to specified
torque.
MANUAL TRANSAXLE <FWD> - Transaxle Assembly <F5M33> ,214
16. / 15. INSTALLATION OF LOCK NUTS
10 mm (.40 in.) (1) install the special tool to the splined end of inputshaft.
(2) Screw a bolt [IO mm (.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handle
to the special tool.
(3) Shift the transaxle in reverse using control lever and

select lever.
(4) Tighten the lock nut to specified torque, while using the
bolt attached in the above step as a spinner handle
stopper.
(5) Loosen the lock nuts.
(6) &tighten the lock nuts to the specified torque.
(7) Stake the lock nut.

MD998245
\ I (1) Install the spring pin using the special tool ,or a pin
punch.
Caution
I I (2) When installing, make sure that the slit of the spring pin
Slit ,+i 1 is aligned with the shift rail center line.
Spring pin
r
, Shift rail
13. APPLICATION OF SEALANT TO AIR BREATHER

Apply specified sealant to air breather mounting portion and
install to the clutch housing.
or equivalent
Transaxle Assembly <F5M33>/
21-42 MANUAL TRANSAXLE <FWD> - 5th Speed Synchionizer Assembly

or MOPAR Part No. 4318032
or ‘equivalent
TFM0041
2. APPLICATION OF SEALANT TO THE REAR COVER

Apply specified sealant to the rear cover.
8” in.) Part No. MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuity.
TFM0044
5TH SPEED SYNCHRONIZER ASSEMBLY NZlMHAK
4 3 1
Disassembly steps TFM0055

1. Reverse brake ring (F5M22-2, F5M33)
2. Stop plate (F5M22-1)
I)4 3. Synchronizer spring
4. Synchronizer sleeve NOTE
WI 5. Synchronizer key (1) Reverse the disassembly procedures to reassemble.
*+ 6. Synchronizer hub (2) ~~ : Refer to “Service Points of Reassembly”.
MANUAL TRANSAXLE <FWD> - 5th Speed Synchr’onizer Assembly tq-43
_ -.‘-
INSPECTION
..- SYNCHRONIZER SLEEVE AND HUB -_
l Combine the synchronizer sleeve and hub and check that
they slide smoothly.
l Check that the sleeve is free from damage at its inside front
and rear ends.
l Check for wear of the hub front end (surface in contact with
the 5th speed gear).
Caution
201044 When replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRING
l Check for wear of the synchronizer key center protrusion.
l Check the spring for weakness, deformation and breakage.
201045

6. INSTALLATION OF SYNCHRONIZER HUB/5. SYN-
CHRONIZER KEY
.Assemble the synchronizer hub, and key noting their
direction.
NOTE
Only the direction of the keys for the F5M22-1 has to be
observed.
TFM0046
3. INSTALLATION OF SYNCHRONliER $PRlNG

Key
Assemble the synchronizer spring so that :its projection
Spring may be engaged in the groove of the synchronizer key.
protrusion
NOTE
Take care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.
2010018
21-44 MANUAL TRANSAXLE <FWD> - Input Shaft Assembly <F5M22>
INPUT SHAFT ASSEMBLY <F5M22> N2tMW
18
16
17 I
Disassembly steps 2060019

*+ 1. Snap ring 13. Synchronizer sleeve
+1)1)+ 2. Ball bearing 14. Synchronizer key
+I) I)+ 3. Bearing sleeve 15. Synchronizer hub
l + 4. Snap ring 16. Synchronizer ring
4+*+ 5. Ball bearing l * 17. 3rd speed gear
l + 6. Spacer 18. Needle bearing
7. 4th speed gear 19. Input shaft
8. Needle bearing
~~ 9. Bearing sleeve NOTE
10. Synchronizer ring (I) Reverse the disassembly procedures to reassemble
(2) l * : Refer to “Service Points of Disassembly”.
l + 11. 3rd-4th speed synchronizer assembly (3) +* : Refer to “Service Points of Reassembly”.
l + 12. Synchronizer spring (4) m : Non-reusable parts
MANUAL TRANSAXLE <FWD> - Input Shaft Assemblir <F5M22> 2145
Remove the front bearing using the special tool as
illustrated. :
MD998801 j, /
:” I’ ’
VI
201048
3. REMOVAL OF BEARING SLEEVE

Remove the bearing sleeve using the special tool as
illustrated.

Remove the ball -bearing together using the special tool as
illustrated.
17. REMOVAL OF 3RD SPEED GEAR
Remove the bearing sleeve, 3rd-4th speed synchronizer
assembly and 3rd speed gear together using the special
tool as illustrated.
INSPECTION
INPUT SHAFT
l Check the outer surface of the input shaft where the needle
bearing is mounted for damage, abnormal wear and seizure
[portion @I.
l Check the splines for damage and wear.
3
NEEDLE BEARING
a Combine the needle bearing with the shaft or bearing
sleeve and gear and check that it rotates smoothly without
abnormal noise or play.
l Check the needle bearing cage for deformation.
201051
Damage, breakage
SYNCHRONIZER RING
/ l Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
peeling.
TFMO119
l Force the synchronizer ring toward the clutch gear and

check clearance “A”. Replace if it is out of specification.
Limit: 0.5 mm (.02 in.)
Synchronizer ring GLar

TFMOlli
SYNCHRONIZER SLEEVE AND HUB

and rear ends.
l Check for wear of the hub end surfaces (in contact with
each speed gear).
Caution
When replacing, replace the synchronizer hub and
sleeve as a set.

l Check the spring for deterioration, deformation and break-
age.
MANUAL TRANSAXLE <FWD> - Input Shaft Assembly <F5M225 ‘zli47
SPEED GEARS
l Check the bevel gear and clutch gear teeth for damage and
wear.
l Check the synchronizer cone for rough surface, damage
and wear.
l Check the gear ‘bore and front and rear ends for damage
and wear.
lami
Near
20105:

12. INSTALLATlON OF SYNCHRONIZER SPRING
Spring
protrusion Install the synchronizer spring so that its protrusion fits into
the groove in the synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
groove of the same key.
2010018
11. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER

ASSEMBLY
(1) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove at
the hub end.
NOTE
If the installation is in the opposite way, press-in might
not be possible. This is because the edge of the hub
inner diameter spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Press the 3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
Caution
When installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-
rectly in respective grooves of the synchronizer
ring.
(3) Check the 3rd speed gear rotates smoothly.
TFM0021
9. INSTALLATION OF BEARING SLEEVE

Use the special tool as illustrated.
MD998320
/
21-48 MANUAL TRANSAXLE <FWD> - lntwt Shaft Assemblv <F5M22>
Some spacers have an inscribed identification mark. For _
such spacers, installation should be so that the surface that.-
has no mark is facing toward the 4th gear side. Spacers -
4th speed without identification mark may be installed” in either
gear side
direction.
TFM004:

Install the ball bearing over the input shaft using the special
tool.
2060006

Install a snap ring so that the input shaft rear bearing end
play will be the standard value.

Using the special tool, attach the bearing sleeve on the
input shaft.
Caution
When press-fitting the sleeve on the input shaft, verify
that the flange of the sleeve fits closely on the bearing. h
MANUAL TRANSAXLE <FWD> - Input Shaft Assemblv <F5M22> 21-49
Install the ball bearing over the input shaft using the sdecial
.e,
tool. *
20105t

Snap rings are available in three different thickness. Select
the thickest one that fits in the snap ring groove.
Caution
Do not cause damage to the input shaft oil seal
contacting portion.
Standard value: 0.01-0.12 mm (.0004-,005 in.)
INPUT SHAFT ASSEMBLY <F5M33> NZlMIAUa
2150009
Disassembly steps
+* l + 1. Taper roller bearing 14. Synchronizer sleeve
++ ~~ 2. Bearing sleeve 15. Synchronizer key
*+ 3. Snap ring 16. Synchronizer hub
++ I)+ 4. Taper roller bearing 17. Synchronizer ring
l + 5. Snap ring 18. 3rd speed gear
I)+ 6. Cone spring 19. Needle bearing
~~ 7. Subgear 20. Input shaft
8. 4th speed gear
9. Needle bearing
NOTE
~~ 10. Bearing sleeve (1) Reverse the disassembly procedures to reassemble.
11. Synchronizer ring (2) ++ : Refer to “Service Points of Disassembly”.
l + 12. 3rd-4th speed synchronizer assembly (3) l + : Refer to “Service Points of Reassembly”.
l * 13. Synchronizer spring (4) m : Non-reusable parts
MANUAL TRANSAXLE <FWD> - lnwt Shaft Assembly <F5M33> 21-51
1. REMOVAL OF TAPER ROLLER BEARING
Remove the front bearing using the special tool as
illustrated.
. .
I I

illustrated.

Remove the taper roller bearing together using the special
18. REMOVAL OF 3RD SPEED GEAR
Remove the bearing sleeve, 3rd-4th, speed synchronizer
assembly and 3rd speed gear together using the special
INSPECTION
INPUT SHAFT
l Check the outer surface of the input shaft where the
needle bearing is mounted for damage; abnormal wear and
seizure [portion @I.
I l Check the splines for damage and wear.
2010x
-
NEEDLE BEARING
l Combine the needle bearing with the shaft or bearing +,
201051
r Damage, breakage
SYNCHRONIZER RING
l Check the clutch gear teeth for damage and breakage.
peeling.
Damage,
TFMO119

Limit: 0.5 mm (.02 in.)
-z
I
Synchronver ring Gear
TFM0117

and rear ends.
each speed gear).
Caution
2010441
sleeve as a set.

l Check the spring for deterioration, deformation and break-
age.
MANUAL TRANSAXLE <FWD> - Incut Shaft Assembly <F5M33i %qd%
SPEED GEARS
l Check the bevel gear and clutch gear teeth for damagew. and
wear.
and wear.
l Check the gear bore and front and rear ends for damage
and wear.

Key 13. INSTALLATION OF SYNCHRONIZER SPRING
Assemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
Take care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.
2010018

ASSEMBLY
the hub end.
NOTE
2nd round indentation is made to facilitate pressing in.
gear
(2) Press the 3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
Caution
When installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-
rectly in respective grooves of the synchronizer
ring.
(3) Check the 3rd speed gear rotates smoothly.
TFM0024

MD998320
20105f j
7. INSTALLATION OF SUB GEAR/G. CONE SPRINGI
5. SNAP RING
install the sub gear and cone spring to 4th gear, and then -
install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing in
the correct direction.
4. INSTALLATION OF TAPER ROLLER BEARING

Install the taper roller bearing over the input shaft using the
special tool.
2nd speed
3. REASSEMBLY OF SNAP RING

(1) Select the thickest possible snap ring which can enter
the snap ring groove.
Standard value: 0.01-0.09 mm (.0004--004 in.)
(2) Using a special tool, attach the snap ring to the input
shaft.
Caution
MD998808 1. Don’t reuse the old snap ring.
(inner) 2. If snap ring pliers are used, the snap ring may
sometimes be expanded excessively. This will h
prevent proper mounting of the sleeve.
MANUAL TRANSAXLE <FWD> - I n p u t S h a f t AsSe’mbly <F!5M33> gq-86
2. REASSEMBLY OF BEARING SLEEVE
(1) Using a special tool, fit the begring sleeye to t$?i~nput
s h a f t . _ ., .L)
Caution
After fitting, check that the sleeve flange is closely
fit to the bearing.

Install the taper roller bearing over the input shaft using the
special tool.
21-56 MANUAL TRANSAXLE <FWD> - Intermediate Gear Assembly
INTERMEDIATE GEAR ASSEMBLY NZlhlJAd
Disassembly steps
l * 1. Snap ring l a 11. Synchronizer ring
w *+ 2. Taper roller bearing l * 12. 2nd speed gear
w 3. Bearing sleeve 13. Needle bearing
4* 4. 1 st speed gear +* ,* 14. Taper roller bearing
5. Needle bearing 15. Intermediate gear
l + 6. Synchronizer ring
ea 7. Synchronizer spring NOTE
w 8. 1 st-2nd speed synchronizer sleeve (1) Reverse the disassembly procedures to reassemble.
l * 9. Synchronizer key (2) +e : Refer to “Service Points of Disassembly”.
+* ~~ 10. 1 st-2nd speed synchronizer hub
(4) III : Non-reusable parts
MD998801 SERVICE POINTS OF DISASSEMBLY

2. REMOVAL OF TAPER ROLLER BEARING/Q. 1ST SPEED
GEAR
Remove the taper roller bearing, 1 st speed gear and bearing
sleeve using the special tool as illustrated.
Caution
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller
bearing as a set.
MANUAL TRANSAXLE <FWD> - Intermediate Gear Assembly 2MJ
10. REMOVAL OF lST-2ND SPEED SYNCHRONIZER HUB/

12. 2ND SPEED GEAR
Remove the 1 st-2nd speed synchronizer assembly and 2nd
speed gear together using the special tool as illustrated.

Caution
1. Do not reuse the bearing removed from the shaft.
bearing as a set.
INSPECTION
INTERMEDIATE GEAR
l Check the outer surface of the intermediate gear where the
needle bearing is mounted for damage, abnormal wear and
seizure [portion @.I
Spline 201065
NEEDLE BEARING
l Combine the needle bearing with the shaft or bearing
r Damage, breakage
SYNCHRONIZER RING
l Check the clutch gear teeth for damage and breakage. ~
peeling.
Damage, wear l-FM0119 J

Limit : 0.5 mm (.02 in.)
I I
Synchronizer ring Gear
TFM0117

l Check that the sleeve is free from damage at its inside front -4r
and rear ends. -.--
each speed gear).
Caution
sleeve aS a set.
l Check the spring for weakness, deformation and breakage.
201045
SPEED GEARS
l Check the bevel gear and clutch gear teeth for damage and
wear.
and wear.
l Check the gear bore and front and rear ends for damage k
and wear.
MANUAL TRANSAXLE <FWD> - Intermediate Gear AsOembly 21 L59
.-_
SERVICE POINTS OF REASSElViBLY
Install the taper roller bearing over the intermediate gear
using the special tool.
Caution
When installing the bearing, push the inner race only.
11. /6. INSTALLATION OF SYNCHRONIZER RINGS

The 1 st speed synchronizer ring has an identification mark.
10. INSTALLATION OF lST-2ND SPEED SYNCHRONIZER

Front + HUB/S. SYNCHRONIZER KEYi.8. IST-2ND SPEED
SYNCHRONIZER SLEEVE/7. SYNCHRONIZER SPRING
(1) Combine the lst-2nd speed synchronizer hub and
sleeve as illustrated.
Identi-
fication
mark
210031
(2) Assemble the synchronizer spring so that its projection

Key may be engaged in the groove of the synchronizer key.
Spring NOTE
protrusion
(1) Take care to prevent the projections of the front and
rear spring from sitting in the groove of the same
key.
(2) A synchronizer spring different from the one shown
in the figure may be used but the explanation is the
same.
2010018
(2) install the Ist-2nd speed synchronizer assembly over
MD998350 the intermediate gear using the special tool. ,-
/ Caution
1. When installing the synchronizer assembly, -‘
1 st-2nd
make sure that three synchronizer keys are
speed seated correctly in respective grooves of the
synchronizer synchronizer ring.
assembly 2. After installation of synchronizer assembly,
check that the 3rd speed gear rotates smoothly.
3. INSTALLATlON OF BEARING SLEEVE

Install the 1 st speed gear and bearing sleeve together over
the intermediate gear using the special -tool.
r%
-.
201069

Install the taper roller bearing over the intermediate using
. MD998350 the special tool.
Caution
I
3 210024

Select and install a snap ring that will result in an
intermediate gear bearing end play that is the standard
value.
Standard value: 0.01-0.14 mm (.0004-.OOS in.) h
MANUAL TRANSAXLE <FWD> - Output Shaft Assembly 21-61
OUTPUT SHAFT ASSEMBLY NZlMKAG
# - DISASSEMBLY AND REASSEMBLY
.C
Disassembly steps NOTE

(I) Reverse the disassembly procedures to reassemble
+* .+ 1. Taper roller bearing (2) +e : Refer to “Service Points of Disassembly”.
4* w 2. Taper roller bearing (3) W : Refer to “Service Points of Reassemby”.
3. Output shaft
210028

Press
1./2. REMOVAL’ OF TAPER ROLLER BEARINGS
Remove the taper roller bearing using the special tool as
illustrated.
Caution
AD9d880.l
1. Do not reuse the bearings removed from the shaft.
bearing as a set.
il
7inn75
-. ----
I

MD998350 1./2. REMOVAL OF TAPER ROLLER BEARINGS
install the taper roller bearing using the special tool.
Caution
210026
21-62 MANUAL TRANSAXLE <FWD> - Shift Rails and Forks
SHIFT RAILS AND FORKS N21-
DISASSEMBLY AND REASSEMBLY sb
disassembly steps
1, 1 st-2nd speed shift fork
2. 1 st-2nd speed shift rail 6. 3rd-4th speed shift rail
3. 3rd-4th speed shift fork 7. Reverse shift lug
4. 5th-reverse speed shift rail
** 5. Interlock plunger NOTE
(2) l *: Refer to “Service Points of Reassembly”.
201073
Interlock Reverse shift lug SERVICE POINTS OF REASSEMBLY

5. INSTALLATION OF INTERLOCK PLUNGER
insert the interlock plunger at illustrated position of the
3rd4th speed shift rail.
“r
3rd-4th speed shift rail 2ojoaa

MANUAL TRANSAXLE 4WD> - Differential Assembly 21-63
DIFFERENTIAL ASSEMBLY NZlMMAF
. DISASSEMBLY AND REASSEMBLY

Disassembly steps
l + 1. Bolt
2. Differential drive gear
l l a 3. Taper roller bearing
+e l + 4. Lock pin
M 5. Pinion shaft
l 6. Pinion
e+ 7. W a s h e r
l + 8. Sidegear
l + 9. Spacer (Select)
10. Differential case
130-440 Nm
94- 101 ft.lbs.
\6
NOTE
(2) ~~ : Refer to “Service Points of Disassembly”.
(3) ,+ : Refer to “Service Points of Reassembly”.
(4) p : Non-reusable parts
163025
Press SERVICE POINTS OF DISASSEMBLY

F+ Bearing
Remove the taper roller bearing using the special tool as
illustrated.
Caution ’
1. Do not reuse the bearing removed from the dif-
ferential case.
bearing as a set.
21-64 MANUAL TRANSAXLE <FWD> - Differential Assembly
Lock pin Drive out the lock pin from the hole A using a punch.
2150020

9. INSTALLATION OF SPACER / 8. SIDE GEAR / 7.
WASHER / 6. PINION / 5. PINION SHAFT
(1) Install the spacer on the back of the side gear and then
install the gear in the differential case.
Caution
When installing a new side gear, use a spacer of
medium thickness [0.93-1.00 mm (.36-.04 in.)].
(2) Set the washer on the back of each pinion and insert the
two pinions to specified position while engaging them
with the side gears and turning them.
(3) Insert the pinion shaft.
(4) Measure the backlash between the side gears and

pinions.
Standard value:
0.025-0.150 mm LOO1 -.006 in.)
(5) If the backlash is out of specification, disassemble again
and using correct spacer, reassemble and adjust.
Caution
Adjust for same backlash of both side gears.

Differen-
Lock pin tial case Align the pinion shaft lock pin hole with the case lock pin
hole and insert the lock pin.
alla-
ctiol Caution
1. Do not reuse the lock pin.
2. The lock pin head must be sunk from the flange
surface of the differential case.
Llock pin end with
la 2150021
bierential Assembl /
MANUAL TRANSAXLE <MD> - SDeedometer Gear ksemblv
,. Install the taper roller bearings on bqth sides of the
Bearing differential case.
Caution
When press-fitting the bearings, push the inner race
only.
TFYOOIO
1. INSTALLATION OF BOLTS
Apply spec.ified adhesive to the entire threads of the bolts
and quickly tighten in the order shown to specified torque.
or equivalent
Caution
If a bolt is reused, remove traces of old adhesive
The numerals 0 to (8 indicate completely from the threads.
1 the tiqhtening Gequeice. 210029
I
SPEEDOMETER GEAR ASSEMBLY NZlMNAB
Disassembly steps
1. O-ring
l 4 2. Spring pin
~4 3. Speedometer driven gear
4. Oil seal
5. Sleeve
NOTE
(2) ,+ : Refer to “Service Points of Reassembly”.
(3) q : Non-reusable parts 201078

3. INSTALLATlON OF SPEEDOMETER DRIVEN GEAR
Apply gear oil sparingly to the speedometer driven gear
shaft and insert the shaft.

Install the spring pin in such a way that its slit does not face
Slit
the gear shaft.
21-66 MANUAL TRANSAXLE <FWD> - Clutch Housing Assembly
CLUTCH HOUSING ASSEMBLY NZlMPAL
DISASSEMBLY AND REASSEMBLY 2=

-,_
15-22 Nm
11-15 ftlbs.
L--
20-27 Nm
15-19 ft.lbs.
2100019
Disassembly steps
1. Bolt l * 16. Needle bearing
2. Select lever assembly l a 17. Needle bearing
3. Select lever shoe ;EJ. Fil;tch housing
4. Interlock place bolt
5. Gasket 20: Return spring
+e l * 6. Lock pin 21. Stopper plate
j\ l * l * 7. Spring pin 22. Spring pin
8. Neutral return spring
9. Stopper body
10. Control finger
11. Interlock plate
NOTE
12. Neutral return spring assembly (1) Reverse the disassembl procedures to reassemble.
13. Control shaft (2) ~~ : Refer to “Service 6.
ornts of Disassembly”.
14. Control shaft boot (3) l + : Refer to “Service Points of Reassembly”.
l 4 15. Oil seal (4) q : Non-reusable parts
MANUAL TRANSAXLE <RND> - Clutch Housing Assembly 2f-67

MD998019 6. REMOVAL OF LOCK PIN
\
Drive out the lock pin from the control finger using the
\ special tool.
Caution
When removing the lock pin, turn the control lever to,
- Control such position that the lock pin will not contact the
lever
J$p-- clutch housing.
201082

MD998\019
w Drive out the spring pin from the stopper body using the
special tool.
Caution
- When removing the spring pin, pull the control shaft in
the direction illustrated so that the spring pin will not
contact the clutch housing.
20108:

17. / 16. INSTALLATION OF NEEDLE BEARINGS
Install the needle bearing flush with the surface A of the
clutch housing.
Needle bearing ’ ’
20601:

Install the control shaft oil seal using a socket wrench.
Socket
wrench
I ’I 20108!
7./6. INSTALLATION OF SPRING PIN AND LOCK PIN

(1) Install new spring pin and lock pin using the special tool.
Caution
Do not reuse the spring pin and lock pin.
(2) install the spring pin with its slit at right angle to the
control shaft center.
21-68 MANUAL TRANSAXLE <AWD> - General Information
MANUAL TRANSAXLE <AWD> ,&

GENERAL INFORMATION --
Clutch housing 1st speec gear

;t-2nd speed synchronizer assembly
Bearing retainer
\ 2nd speed gear
3rd speed gear
3rd-4th speed synchronizer assembly
4th speed gear
5th speed gear
I .
lnpu
Dnve bevel gear I

intermediate gear
APL
ii\ Intermediate
gear
Center shaft
Viscous coupling
Cent& differential
\
Front output shaft
Front differential
TFM0014
2f.46g
MANUAL TRANSAXLE <AWD> 2 S~ecifCca?io’iik
\ ,.. .,
1 L ,, ,‘S. / , , .,‘; ,< ’ ,f. : ,: ; .>r
SPECIFICATIONS “. . .&
. ’ GENERAL SPECIFICATIONS NZ1.pA.B’
Items Specifications (I
.,A I
Model W5M33-2-N PZV
Applicable engine 4G63
Type 5-speed transaxle floor shift
Gear ratio
1 st 3.083
2nd I .684
3rd 1.115
4th 0.833
5th 0.666
Reverse 3.166
Reduction ratio
Primary 1.275
Front differential 3.866
Transfer 1.090
Speedometer gear ratio (driven/drive) 29136
Oil quantity lit. (qts.)
Transaxle 2.3 (2.43)
Transfer 0.6 l.63)
SERVICE SPECIFICATIONS N21CB-B
Items Specifications mm,.(in.)
Standard value
Transaxle
Input shaft end play o-0.05 (O-.002)
Input shaft rear bearing end play 0.01-0.09 (.0004-,004)
Intermediate gear preload 0.08-0.14 (.0031-,006)
Intermediate gear bearing end play 0.01-0.11 (.0004-,004)
Front output shaft preload 0.08-0.13 (.0031-,005)
Center differential
Viscous coupling end play 0.1-0.26 (.0039-.OlO)
Differential case preload 0.08-O. 13 LOO31 - ,005)
Differential pinion backlash 0.025-0.150 LOO01 -.006)
Front differential
Differential case end play 0.05-0.17 (.0020-,007)
Differential pinion backlash 0.025-0.150 (.OOOl-,006)
Transfer
Bevel gear set backlash 0.08-0.13 (.0031-.005)
Driven bevel gear turning drive torque 1 .O- 1.7 Nm (0.72- 1.23 ft.lbs.1
d-...
Drive bevel gear shaft turning drive torque 1.7-2.5 Nm (1.23-1.81 ft.lbs.1
21-70 MANUAL TRANSAXLE <AWD> - Specifications
SNAP RING (FOR ADJUSTMENT) AND SPACER

Identification Part No “
Part name Thickness mm (in.) symbol
Snap ring 0.80 (.0315) 80 MD72766j

(For input shaft rear bearing end play) 0.83 (.0327) 83 MD720937
0.86 l.0339) 86 MD720938
0.89 (.0350) 89 MD720939
0.92 (.0362) 92 M D720940
0.95 (0374) 95 MD720941
0.98 (.0386) 98 MD720942
1 .Ol (.0398) 01 MD720943
1.04 (.0409) 04 M D720944
1.07 (0421) 07 M D720945
1 .lO (0433) J MD710454
1 .13 (.0445) D MD700270
1.16 (0457) K MD71 0455
1 .I9 (0469) L MD71 0456
1.22 (0480) G MD700271
1.25 (.0492) M MD710457
1.28 (0504) N MD7.10458,
1.31 (.0516) E MD706574
1.34 (.0528) 0 MD71 0459
1.37 (.0539) P MD71 0460
1.40 (.0551) None MD706573
1.43 (.0563) Q MD71 0461
1.46 (.0575) R MD71 0462
Spacer 0.80 (.0315) 80 MD720948

(For adjustment of intermediate gear preload) 0.83 (.0327) 83 MD720949
0.86 (.0339) 86 MD720950
0.89 (0350) 89 MD726951
0.92 (0362) 92 MD720952
0.95 (0.374) 95 MD720953
0.98 (0386) 98 MD720954
1 .Ol (.0398) 01 MD720955
1.04 (.0409) 04 MD720956
1.07 (0421) 07 M D720.957
1.10 (0433) 10 MD720958
1.13 (0445) 13 MD720959
1.16 (.0457) 16 MD720960
1.19 i.0469) 19 MD726961
1.22 (.0480) 22 MD720962
1.25 (.0492) 25 M D7 12346
1.28 (.0504) 28 MD712347
‘I .31 (.0516) 31 MD712348
1.34 (0528) 34 MD712349
1.37 (.0539) 37 MD712329
1.40 (.0551) 40 MD712330
1.43 (0563) 43 MD712331
21”;‘)r’ ”
MANUAL TRANSAXLE <AWD> - Specificatihg
Identification
Part name Thickness mm (in.) Part No.,
symbol
Snap ring 1.40 (0551) None MD703779,:

(Fo; x&tment of intermediate gear bearing 1 .50 (6591) Brown MD703786 ,. r
1.60 (.0630) Blue MD703781
Spacer 1.28 (0504) B28 MD7261 67
(For adjustment of front output shaft preload) 1 .31 (.05I6) B37 MD7261 68
1.34 (0528) B34 MD7261 69
1.37 (.0539) B37 M D724326
1.40 (0551) B40 MD724327
1.43 (.0563) B43 MD724328
1.46 (0575) B46 MD724329,
:,
1.49 (.0587) B49 M D724330
1.52 (.0598) B52 MD724331
1.55 (0610) B55 MD724332
1.58 (.0622) B58 MD724333
1.61 (.0634) B61 MD724334
1.64 (.0646) B64 M D724335
1.67 (.0657) B67 MD724336
1.70 (.0669) B70 MD724337
1.73 (0681) B73 M D724338
1.76 (.0693) B76 MD724339:
1.79 (.0705) B79 M D724340
1.82 (0717) B82 M D724341
1.85 (0728) B85 MD724342
1.88 (0740) B88 M D724343
1.91 (0752) B91 MD724344
Snap ring 1.30 (0512) Orange MD727650

(For adjustment of viscous coupling end play) 1 .40 (,055~) Red MD720686
1.50 (.0591) Blue MD720687
1.60 (0630) None M D720688
1.70 (.0670) White MD720689
1.80 (.0709) Yellow MD720690
1.90 (.0748) Green MD727651
Spacer 1 .I 3 (.0445) 13 M D736928
(For adjustment of center differential case
preload) I. 16 (0457) 16 MD736929
I .I 9 (.0469) I9 MD736751
1.22 (0480) 22 MD736931
1.25 (.0492) 25 MD7261 66
1.28 (.0504) 28 MD718517 ’
1.31 (.0516) 31 MD718518
I .34 (.0528) 34 MD718519
1.37 (.0539) 37 M D7 18520
1.40 (.0551) 40 MD71 8521
1.43 (.0563) 43 MD718522
I .46 (.0575) 46 MD7 18523
1.49 (.0587) 49 MD71 8524
I .52 (.0598) 52 MD718525
1.55 (.0610) 55 MD718526
Identification
Part name Thickness mm (in.) Part No.
symbol
Spacer 1.58 (.0622) 58 MD718527
(For adjustment of center differential case
preload) 1.61 (0634) 61 MD71 8528
1.64 (.0646) 64 MD718529
1.67 (0657) 67 MD71 8530
1.70 (.0669) 70 MD71 8531
1.73 (.0681) 73 MD721 959
1.76 i.0693) 76 MD721 960
1.79 (.0705) 79 MD721 961
Spacer 2.09-2.16 (.0823-.0850) 0 M D730350
(For adjustment of center differential pinion 2.17-2.24 (.0854-,0882) 9 MD730349
backlash-Front side)
2 . 2 5 - 2 . 3 2 (.0886-.0913) 8 M D730348
2 . 3 3 - 2 . 4 2 (.0917-.0953) 7 M D730347
2.43-2.50 (.0957-.0984) 6 M D730346
2.51-2.58 (.0988-.1016) 5 MD730345
2 . 5 9 - 2 . 6 6 (.1020-.1047) 4 M D730344
2 . 6 7 - 2 . 7 4 (.1051-.1079) 3 M D730343
2 . 7 5 - 2 . 8 2 (.1083-.I 1 1 0 ) 2 M D730342
Spacer 0.59-0.66 (.0232-.0260) 74 M D724974
(For adjustment of center differential pinion 0.67-0.74 (,0264-.0291) 50 M D724950
backlash- Rear side)
0.75-0.82 (.0295-.0323) 80 MD720680
0.83-0.92 (.0327-.0362) 79 MD720679
0.93-I .OO (.0366-.0394) 78 MD720678
1 .01-l .08 (.0398-.0425) 76 MD720676
1.09-I .I6 (.0429-.0457) 77 MD720677
1 . 1 7 - 1 . 2 4 (.0461-.0488) 49 M D724949
Spacer 0 . 5 6 (.0220) 56 MD727658
6:;or)adjustment of front differential case end 0.65 (,0256) 65 MD727659
0 . 7 4 (.0291) 74 MD727660
0 . 8 3 (.0327) 83 MD720937
0 . 9 2 (0362) 92 MD720940
1 .Ol (.0398) 01 MD720943
1.10 f.0433) J MD71 0454
1 .I9 (.0469) L MD71 0456
1 . 2 8 (.0504) N MD710458
1 . 3 7 (.0539) P MD71 0460
Spacer 0.75-0.82 (.0295-.0323) - MA1 80862
IFor adjustment of front differential pinion
sacklash) 0.83-0.92 (.0327-.0362) - MA1 80861
0.93-I .OO (.0366-.0394) - MA1 80860
1 .01-l .08 (.0398-.0425) - MA1 80875
1.09-I .I6 (.0429-.0457) - MA1 80876
MANUAL TRANSAXLE <AWD> - Specifications 2’7 -73
Identification
Part name Thickness mm (in.) Part No.
symbol
Spacer 1.34 (.0528) 34 MD723600
(For adjustment of drive bevel gear mount) 1,37 (.0539) 37 MD723601,
1.40 (.0551) 40 MD723602
1.43 (.0563) 43 MD723603
1.46 (.0575) 46 MD723604
1.49 (.0587) 49 M D723605
1.52 l.0598) 52 MD723606
1.55 (0610) 55 M D723607
1.58 (0622) 58 M D723608
1.61 (.0634) 61 M D723609
1.64 (.0646) 64 MD7261 70
1.67 (0657) 67 MD7261 71
Spacer 1.28 (.0504) 628 MD7261 67
(For adjustment of drive bevel gear train
preload) 1.31 (.0516) 631 MD7261 68
1.34 (0528) B34 MD7261 69
1.37 (.0539) B37 MD724326
1.40 (.0551) B40 MD724327
1.43 (.0563) B43 MD724328
1.46 (.0575) B46 MD724329
1.49 (.0587) B49 M D724330
1.52 (.0598) B52 MD724331
1.55 (0610) B55 MD724332
1.58 (.0622) B58 M D724333
1.61 (.0634) B61 M D724334
1.64 (0646) B64 MD724335
1.67 (0657) B67 MD724336
1.70 1.0669) B70 MD724337
1.73 (.0681) B73 MD724338
1.76 1.0693) B76 MD724339 :.
1.79 (0705) 879 M D724340
1.82 (.0717) B82 MD724341 .
1.85 (0728) B85 M D724342 1
Spacer 1 .I9 l.0469) 19 MD726172
(For adjustment of driven bevel gear train
preload) 1.22 (.0480) 22 MD722081
1.25 (.0492) 25 MD722682 :
1.28 (0504) 28 MD722683
1.31 (.0516) 31 MD722084 i_
1.34 (.0528) 34 MD722085.
1.37 (.0539) 37 MD722086
1.40 (.0551) 40 MD722087
1.43 (.0563) 43 MD722088
1.46 (.0575) 46 M D722089
1.49 (.0587) 49 MD722090
1.52 i.0598) 52 MD722091
1.55 (.0610) 55 MD722692
1.58 (.0622) 58 M D722093
Identification
Part name Thickness mm (in.) symbol Part No.
Spacer 1.61 (.0634) 61 MD722094

(For adjustment of driven bevel gear train
preload) 1.64 (.0646) 64 MD722095
1.67 (0657) 67 MD722096
1.70 (.0669) 70 MD722097
1.73 (0681) 73 MD722098
1.76 (.0693) 76 M D722099
1.79 (0705) 79 MD7221 00
1.82 (0717) 82 MD7221 01
1.85 (.0328) 85 MD7221 02
1.88 (.0740) 88 MD7221 03
1.91 (.0752) 91 MD7221 04
1.94 (0764) 94 MD722105
Spacer 0.13 (0051) 13 MD720353
(For adjustment Of driven bevel gear mOWIt) o,16 ( 0063) 16 M D720354
0.19 (0075) 19 MD720355
0.22 (.0087) 22 MD720356
0.25 (.0098) 25 MD720357
0.28 (.Ol IO) 28 MD720358
0.31 (0122) 31 MD720359
0.34 (0134) 34 MD720360
0.37 (0146) 37 MD720361
0.40 (0517) 40 M D720362
0.43 (.0169) 43 MD720363
0.46 (0181) 46 MD720364
0.49 (.0193) 49 MD720365
0.52 (0205) 52 MD720366
TORQUE SPECIFICATIONS NZlCC-B
TRANSAXLE
Items Nm ft.lbs.
Bell housing cover mounting bolt IO-12 7-9
Starter motor mounting bolt 27-34 20-25
Transaxle mount bracket mounting bolt 60-80 43-58
Shift cable and select cable bracket mounting bolt 15-22 11-16
Rear cover mounting bolt 35-42 26-30
Transaxle case mounting bolt 35-42 26-30
Clutch release cylinder mounting bolt 15-22 11-16
Clutch tube to transaxle assembly 15-22 11-16
Transaxle mounting bolt [I2 mm (47 in.) diameter bolt] 43-55 32-39
Transaxle mounting bolt [IO mm (40 in.) diameter bolt] 30-35 22-25
Transaxle mounting bolt [8 mm (.31 in.) diameter bolt] IO-12 7-9
MANUAL TRANSAXLE <AWD> - Specifications 21-75
Items Nm ft.Ibs. ”
Lower arm ball joint to knuckle 60-72 43-52 “
Center bearing bracket installation bolts 36-46 26-33
Right member installation bolt (front) 80-100 58-72
Right member installation bolt (rear) 70-80 51-58
Transfer assembly mounting bolt 55-60 40-43
Poppet plug 30-42 22-30
Backup light switch 30-35 22-25
Restrict ball 30-35 22-25
Speedometer mounting bolt 3-5 2.5-3.5
Oil filler plug 30-35 22-25
Oil drain plug 30-35 22-25
Input shaft lock nut 140-160 102-I 15
Intermediate shaft lock nut 140-160 102-I 15
Center differential drive gear mounting bolt 70-80 5 1 - 5 7
Front differential drive gear mounting bolt 130-140 95-101
Stopper bracket mounting bolt 15-22 11-15
Reverse idler gear shaft mounting bolt 43-55 32-39
Reverse shift lever mounting bolt 15-22 11-15
Bearing retainer mounting bolt 15-22 11-15
Interlock plate mounting bolt 20-27 15-19
Center member mounting bolt 60-80 43-58
Irive shaft center bearing mounting bolt 36-46 2 6 - 3 3
Iriven bevelgearlock nut 140-160 101-115
Select lever assembly mounting bolt 15-22 11-15
3everse brake cone screw bolts 4.0-5.5 2.9-3.9
TRANSFER
Items Nm ft.lbs.
Transfer assembly mounting bolt 55-60 40-43

Cover mounting bolt 8-10 6-7
Extension housing mounting bolt 15-22 II-15
Transfer cover mounting bolt 35-42 26-30
Transfer case adapter mounting bolt 35-42 26-30
Driven bevel gear lock nut 140-160 102-I 15
Hanger bracket mounting bolt 15-22 11-15
LUBRICANTS N21CD.B
Items Specified lubricant Quantity lit. (qts.) I
I Transmission oil
Transfer oil
MOPAR Hypoid gear oil or equivalent,
MOPAR Hypoid gear oil or equivalent,
2.3 (2.43)
0 . 6 (.63)
I

21-76 MANUAL TRANSAXLE <AWD> - Specifications/Special Tools
SEALANTS AND ADHESIVES NZlCE-B
-/
Transaxle H-
Items Specified sealants and adhesives 1

Transaxle case-clutch housing mating surfaces Mitsubishi genuine part No.997740
Transaxle case-adapter mating surfaces or equivalent
Adapter-rear cover mating surfaces
Front differential drive gear bolts M O P A R p a r t No.4318031 or MOPAR part

Center differential drive gear bolts No. 4318032 or equivalent
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
Air breather MOPAR part No.4318025 or equivalent
Transfer
Items Specified sealants and adhesives
Adapter-extension housing mating surfaces Mitsubishi genuine part No. MD997740

or equivalent
Air breather MOPAR part No.4318025 or equivalent
SPECIAL TOOLS NZlDA-B AI
,“I Nllmher
. .-. * ,--. Name
.-...- I Use
---
~ MD99801 9 Lock pin extractor Removal of spring pin and lock pin
MD998245 Lock pin installer Installation of spring pin and lock pin
MD998304 Oil seal installer Installation of front output shaft bearing and
transfer extention housing oil seal
MD998320 Bearing installer Installation of input shaft bearing and input

shaft gear
MANUAL TRANSAXLE <AWD> - Special Tools 21-77
MD998321 Oil seal installer Installation of input shaft front oil seal
M D998323 Bearing installer Installation of rear output shaft oil seal and
transfer case oil seal
MD998325 Differential oil seal Installation of differential oil seal

installer
MD998350 Bearing installer Installation of front output shaft, intermediate

gear, transfer drive bevel gear, and
intermediate gear
MD998369 Bearing installer Installation of input shaft front bearing
MD998801 Bearing remover Removal of input shaft, intermediate gear, ant

output shaft bearing and gears
MD998802 Input shaft holder nstallation and removal of input shaft and
Ttermediate gear lock nut
M D998803 Differential oil seal lstallation of differential oil seal

installer
MD998806 Wrench adapter rdjustment of tooth contact and inspection of

Jrning drive torque
xstallation of input shaft rear snap ring

21-78 MANUAL TRANSAXLE <AWD> - Special Tools
MD99881 9 Installer adapter (40) Installation of front differential bearings
M D998820 Installer adapter (42) Installation of center differential bearings and

driven bevel gear bearing
MD999566 Claw Removal of bearing outer race from

intermediate gear, front output shaft, and
center differential
MD998827 Installer adapter (56) Installation of drive bevel gear bearing
MB990326 Preload socket Measurement of drive bevel gear shaft

rotating torque
M B990900 Side gear holding Measurement of drive bevel gear shaft

(included in Tool (A) rotating torque
MB990988)
MB991 013 Special spanner Installation and removal of driven bevel gear
lock nut
MB991 193 Plug Prevention of transfer oil discharge and

foreign object entry
- Troubleshooting/Service Adjustment Procedures m-79
MANUAL TRANSAXLE <AWD>
TROUBLESHOOTING NIlEAAE
Refer to P.21-12.
SERVICE ADJUSTMENT PROCED’URES

TRANSAXLE OIL LEVEL INSPECTION N2lFBAB1
--/ OQA0024
09FOll
TRANSAXLE OIL REPLACEMENT N2lFCAH
(1) Position vehicle on a flat level and remove filler and drain
plugs to drain transaxle oil.
(2) Pour in fresh transaxle oil through filler port until it reaches
the bottom of filler port.
Transaxle oil: MOPAR Hypoid gear oil or equivalent,
API classification GL-4 or higher.
Transaxle: 2.3 liters (2.4 qts.)
Transfer: 0.6 liter (.6 qt.)
21-80 MANUAL TRANSAXLE <AWD> - Service Adjustment Procedures
DRIVE SHAFT OIL SEALS REPLACEMENT NZlFDAF
(1) Disconnect the drive shaft from the transaxle. Pa

(Refer to GROUP 2 - Drive Shaft.) s-
(2) Remove the transfer assembly.
I I 09K567
09K561
(4) Install the oil seals using the following procedure:

For L.H. For R.H. Using the special tool, tap the oil seal into the transaxle.
Note that there are two types of oil seals, one for R.H. and
the other for L.H., and the shape of each type is different,
-.
as shown.
TRANSFER OIL SEAL REPLACEMENT N2lFGAF
(1) Pull out the propeller shaft from the transaxle. (Refer to
GROUP 16 - Propeller Shaft.)
Service Adjustment Procedures/Transaxle Control/
MANUAL TRANSAXLE <AWD> - SW Lever Assembly 2%8T
(3) Using the special tool, tap the drive shaft oil seal into ,the
transaxle. ;
(4) Apply a coating of the transaxle.
Transaxle oil: MOPAR Hypoid gear oil or equivalent,
API classification GL-4
SPEEDOMETER CABLE REPLACEMENT NZlFEAH
Refer to P.21-14.
TRANSAXLE CONTROL NZl JA-B
Refer to P.21-15.
SHIFT LEVER ASSEMBLY NZlGE-B
Refer to P.21-18.
21-82 MANUAL TRANSAXLE <AWD> - Transaxle
TRANSAXLE
REMOVAL AND INSTALLATION NZlMA-B -

l Removal of the Battery @Installation of the Battery
*Draining of the Transaxle Oil (Refer to P.Zl-13.) *Supplying of Transaxle Oil (Refer to P.21-13.)
@Removal of the Air Hose *Installation of the Air Hose
(Refer to GROUP 11 -Air Cleaner.) (Refer to GROUP II-Air Cleaner.)
*Checking the Operation of the Shift Lever
@Checking the Operation of the Meters and Gauges
27-34 Nm 60-60 Nm* 60-80 Nm

20-25 ft.lbs. 43-58/t.,b~43-58 ft.lbs.
11-16 ftlbs. \
15-22
,“rr,s.
IO-1 6 Nm
7-11 ftlbs.
15-22 Nm vt
11-16 ft.lbs.
09AOl44
Removal steps NOTE

1. Cotter pin (2) +e : Refer to “Service Points of Removal”.
2. Connection for select cable (3) I)+ : Refer to “Service Points of Installation”.
3. Connection for shift cable (4) m : Non-reusable parts
*I) 4. Connection for clutch release cylinder (5) For tightening locations indicated by the * symbol, first
5. Backup light switch connector tighten temporarily, and then make the final tightening
6. Connection for speedometer cable with the entire weight of the engine applied to the
l * 7. Starter vehicle body.
8. A;;saxle assembly upper part coupling (6) If the grease has been wiped from the input shaft and
center shaft splines or if the input shaft and center shaft
9. Transaxle mount bracket have been replaced, apply special grease (MOPAR
Multi-mileage Lubricant Part No. 2525035 or equivalent)
to the input shaft and center shaft splines.
MANUAL TRANSAXLE <AWD> - Transaxle
/ 9-13 Nm
7-10 ft.lbs.
30-35 Nm
22-25 ft.lbs.
24-35 Nm
17-25 ftibs
26-33 ft.lbs.
70-80 Nm r
51-58 ft.lbs.
09A0139
10. Under cover

11. Cotter pin
4* I 2. Connection for tie rod end
4* 14. Connection for lower arm ball joint
+e I)* 15. Connection for drive shaft
16. Circlip
:: 18. Transfer assembly
20. Right member NOTE
21. Gusset (1) Reverse the removal procedures to reinstall.
22. Lf:saxle assembly lower part coupling (2) l * : Refer to “Service Points of Removal”.
~~ ~~ 23. Transaxle assembly (4) m : Non-reusable parts
21-84 MANUAL TRANSAXLE <AWD> - Transaxle
SERVICE POINTS OF REMOVAL N21MBAV
4. DISCONNECTION OF CLUTCH RELEASE CYLINDER/

12. TIE ROD END/l4. LOWER ARM BALL JOINT
Refer to P.21-21.

<R-H.>
Insert a pry bar between the transaxle case and the drive
shaft, and then pry the drive shaft from the transaxle.
Caution
1. Do not pull on the drive shaft; doing so will damage
the inboard joint; be sure to use the pry bar.
2. Do not insert the pry bar so deep as to damaged the
r) ’
Transaxle oil seal.
llKfil1
<L.H.>
(1) Take out the drive shaft by lightly tapping the drive shaft
T.J. case with a plastic hammer.
NOTE
Remove the drive shaft with the hub and knuckle, etc.,
as an assembly.
Caution
1. Removing the drive shaft from the,, outboa,rd
joint side can cause damage to the inboard joint.
Always use a plastic hammer, etc., to remove
the drive shaft.
2. Tapping on the center bearing can damage it.
Never tap on the bearing.
Refer to GROUP 1 l-Exhaust Pipe and Main Muffler.
Refer to P.21-85.
23. REMOVAL OF TRANSAXLE ASSEMBLY
Refer to P.21-22.
!’ NZlMDAQ
23. REMOVAL OF TRANSAXLE ASSEMBLY

Refer to P.21-22.
15. INSTALLATION OF DRIVE SHAFT
Refer to P.21-22.
7. INSTALLATION OF STARTER
Refer to P.21-22.
MANUAL TRANSAXLE <AWD> - Transfer 24-85
TRANSFER
1
--- REMOVAL AND INSTALLATION NZlMAk
55-60
40-43
Removal steps NOTE

1. Front exhaust pipe (2) +I) : Refer to “Service Points of Removal”.
2. Transfer assembly (3) q : Non-reusable parts.
(4) If the grease has been wiped from the center shaft
spline or if the center shaft has been replaced, apply
special grease (MOPAR Multi-mileage Lubricant Part
No.2525035 or equivalent) to the center shaft splrne.
SERVICE POINTS OF REMOVAL NZlMBAU

Refer to GROUP 11 -Exhaust Pipe and Main Muffler.
After moving the transfer assembly to the left and lowering,
the front side, then remove it from the propeller shaft.
Caution
1. Be cautious to avoid damaging the transfer oil seal
ODA0027
lip.
2. The propeller shaft should be suspended so that it’
is not sharply bent.
3. Cover the transfer opening with the special tool to
prevent transaxle oil discharge and the entry of
foreign objects.
B991193
oepoo44
21-86 MANUAL TRANSAXLE <AWD> - Transaxle Assembly
TRANSAXLE ASSEMBLY
30-35 Nm
22-25 Wbs.
30-35 Nm
22-25 ft.lbs.
\ 4.0-5.5 Nm
\ 6 2.9-3.9 ft.lbs. 35-42 N m
7 26-30 ft.lbs.
-42 N m llI8-59
- 3 0 ft.lbs.
- 1
I
21 I
140-160 Nm
102-115 ft.lbs.
/ w ” 16Bl
Y
22
TFMOOZS
Disassembly steps
l + 1. Rear cover ++ I)+ 15. Lock nut
2. Wave spring +e l 4 16. Lock nut
I)+ 3. Screw bolts l + 17. 5th speed synchronizer assembly
4. Reverse brake cone ~~ 18. Shift fork
;. E;zk;p light switch 19. Synchronizer ring
20. 5th speed gear
7: Restrict ball assembly 21. Needle bearing
8. Gasket 22. 5th speed intermediate gear
.-9. Poppet
^ plug i
1 U. Poppet spring NOTE
11. Poppet ball (1) Revers_e the assembly di?: ’ proceaures
’ 10 reassemble.
I 2. Speedometer driven gear assembly
(2) ry : KeTer+-to Service Points of Disassembly”.
l + 13. Air breather (3) +v : neler
“-I-- I- 10 “Service Points of Reassembly”.
l * l 4 14. Spring pin (4) IW
-: N o n - r e u s a tyle parts.
MANUAL TRANSAXLE <AWD> - Transaxle Assembly 21-81
-- i5 r)
p$---
al37
36
43-55 N m
32-39 ft.lbs.
TFM0029
Disassembly steps
I)+ 23. Snap ring
4* 24. Viscous coupling
l 4 25. Steel ball
26. Center shaft
l 27. Transaxle case adapter
28. Outer race
l * 29. Spacer
30. Outer race
l 4 31. Spacer
32. Outer race
l * 33. Spacer
34. Center differential $?everse the disassembly procedures to reassemble.
4* 35. Outer race (2) +I) : Refer to “Service Points of Disassembly”.
l + 36. Reverse idler gear shaft bolt (3) l + : Refer to “Service Points of Reassembly”.
37. Gasket (4) m : Non-reusable parts.
15-22 Nm
11-15 ft.lbs. -.@&
35-42 N m
26-30 ft.lbs.
15-22 Nm
11-15 ft.lbs.
/ 4?
2250013
Disassembly steps
38. Clutch oil line bracket
l + 39. Transaxle case
l + 40. Oil guide
l + 41. Oil guide
42. Outer race
l + 43. Spacer
l * 44. Spacer
45. Stopper bracket
l 46. Oil seal
47. Reverse shift lever assembly
48. Reverse shift lever shoe
49. Reverse idler gear shaft
50. Reverse idler gear NOTE
51. Front output shaft assembly (I) Reverse the disassembly procedures to reassemble.
52. Needle bearing (2) l + : Refer to “Service Points of Reassembly”.
53. Front differential (3) m : Non-reusable parts.
MANUAL TRANSAXLE <AWD> - Transaxle Assembly
6?
--
TFM0666
Disassembly steps
*I) l + 54. Spring pin l 4 66. Oil seal
+I) l + 55. Spring pin l 4 67. Oil seal
+e e+ 56. Shift rail assembly l + 68. Magnet
l + 57. Bolt W 69. Magnet holder
58. Bearing retainer 70. Clutch housing assembly
+e l + 59. Intermediate gear assembly
s: W 60. Input shaft assembly
61. Outer race NOTE
4* 62. Outer race (1) Reverse the disassembly procedures to reassemble.
63. Oil guide (2) +I) : Refer to “Service Points of Disassembly”.
4* 64. Outer race (3) ~~ : Refer to “Service Points of Reassembly”.
l 4 65. Oil seal (4) m : Non-reusable parts.
SERVICE POINTS OF DISASSEMBLY NZlMFAT
14. REMOVAL OF SPRING PIN rii

Remove the spring pin using the special tool. .,
15.116. REMOVAL OF LOCK NUTS

gear.
(2) Shift the transaxle into reverse using the control lever
and select lever.
(3) Install the special tool on the input shaft.

(4) Install the spinner handle and 10 mm (.039 in.) bolt.
(5) Remove the lock nuts.
A
MANUAL TRANSAXLE <AWD> - Transaxle Assembly 21-91,
24. REMOVAL OF VISCOUS COUPLING
Using a flat-blade screwdriver, pry off the viscous coupling
little by little.
35. REMOVAL OF OUTER RACE

Using the special tool, remove the outer race.
54.155. REMOVAL OF SPRING PINS

Remove the spring pins using the special tool.
56. REMOVAL OF SHIFT RAIL ASSEMBLY

(1) Shift the Ist-2nd speed shift fork into 2nd speed.
(2) Shift the 3rd-4th speed shift fork into 4th speed.
(3) Rotate the shift controls in the direction of the arrow in
numerical order. Remove the shift lugs from the control
finger and interlock plate.
(4) Raise each of the shift rails upward and remove them
from the clutch housing.
(5) Remove the all shift rails and forks.
59. REMOVAL OF INTERMEDIATE GEAR ASSEMBLY/

60. INPUT SHAFT ASSEMBLY
Lift up the input shaft assembly and remove the intermedi-
ate gear assembly.
61./62./64. REMOVAL OF OUTER RACE

Using the special tool, remove the outer race.
SERVICE POINTS OF REASSEMBLY N21MGAPa
69. INSTALLATION OF MAGNET HOLDER/68. MAGNET

Install the magnet and magnet holder, ensuring they are
installed in the correct direction.

Using the special tool, install the rear output shaft oil seal.
MANUAL TRANSAXLE <AWD> L Transaxle Assenibty 21-93
For L.H. For R.H.
Using the special tool, install the drive shaft oil seals,
Dust making sure that the seal for each side is in its proper
location.
Caution
Make sure that the notch in the L.H. oil seal flange is on
the up side where it is installed.
,’ *

Using the special tool, install the input shaft front oil seal.
60. INSTALLATION OF INPUT SHAFT ASSEMBLY/

59. INTERMEDIATE GEAR ASSEMBLY
Lifting up the input shaft assembly, install it together with
the intermediate gear assembly.
57. INSTALLATION OF BOLT
Apply adhesive to the bolt threads.
or equivalent
Caution
Be careful not to apply to adhesive to the bold head.
5mm
(.21 in.) TFM0063
56. INSTALLATION OF SHIFT RAIL ASSEMBLY

(1) Shift the Ist-2nd synchronizer sleeve into 2nd speed.
(2) Shift the 3rd-4th synchronizer sleeve into 4th speed.
(3) Fit the shift forks of shift rail assembly to their groove of
sleeves.
(4) Install the shift rails, rail holes of clutch housing.

plate.
55./54. INSTALLATION OF SPRING PINS

Using the special tool, drive the spring pins into position.
Make sure that the slit in the spring pin is aligned with the
shift rail centerline.
Caution
MANUAL TRANSAXLE <AWD> - Transaxle Assembly 23-95
Using the special tool, install the drive shaft oil seal.
I -.,
44.143. INSTALLATION OF SPACER

(1) Place two pieces of approximately 10 mm (39 in.) long,
1.6 mm (.06 in.) dia. solder at the locations shown on
the transaxle case and install each outer race.
(2) Place two pieces of approximately 10 mm (.39 in.) long,

1.6 mm (.06 in.) dia. solder at the locations shown on
the bearing outer race.
(3) Install the transaxle case, and tighten bolts to specifiea-
tion.
(5) Remove the outer races and remove the solder.
(6) If the solder is not broken, carry out the work in steps
(7) Using a micrometer, measure the thickness of the

flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Front output shaft preload
0.08-0.13 mm (.0031-.005 in.)
Front differential case end play
0.05-0.17 mm (.0020-.a07 in.)
41./40. INSTALLATION OF OIL GUIDE
Install the oil guide or the transaxle case.

Apply sealant (liquid gasket) to the clutch housing side of
the transaxle case.
Specified sealant: Mitsubishi genuine Part
Caution
excess or discontinuities.
._~~ / 1 - 2 mm l.039 - ,078 in.) 2200051
36. INSTALLATION OF REVERSE IDLER GEAR SHAFT BOLT

(1) Center the shaft with a screwdriver [shaft diameter 8
mm (.31 in.) or similar object].
(2) Tighten the reverse idler gear shaft bolt to specification.
33.131.129 INSTALLATION OF SPACER

(1) Place four pieces of approximately 10 mm (.39 in.) long,
1.6 mm (06 in.) dia. solder at the locations shown on
the transaxle case adapter assembly and install each
outer race.
(2) Install the transaxle case adapter assembly and rear A
cover, and tighten bolts to specification.
(3) Remove the transaxle case adapter assembly and rear
cover.
MANUAL TRANSAXLE <AWD> - Transaxle Assemblv
(4) Remove the outer races and remove the solder:
(5) If the solder is not broken, carry out the work in steps,
(6) Using a micrometer, measure ttie thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Input shaft end play
O-.0.05 mm (O-.0020 in.)
Intermediate gear preload
0.08-0.14 mm (.0031-.005 in.)
Center differential case preload
I-2mm ml 0.08-0.13 mm (.0031-,005 in.)
27. INSTALLATION OF TRANSAXLE CASE ADAPTER
Apply sealant (liquid gasket) to the transaxle case side of
the transaxle case adapter assembly.
Specified sealant: Mitsubishi genuine sealant Part
Caution
, excess or discontinuities.
25. INSTALLATION OF STEEL BALL

Move the center shaft so that the steel ball is seated
securely into the groove in center shaft.

Select the snap ring so that the end play in the viscous
coupling is up to specification.
Standard value: 0.1-0.26 mm (.0039-.OlO in.)
Snap r
/ / 221012:3
18. INSTALLATION OF SHIFT FORK/17. 5TH SPEED SYN-

CHRONIZER ASSEMBLY
Mate the 5th speed shift fork with the 5th gear synchroniz-
er assembly and install them simultaneously.
16.115. INSTALLATION OF LOCK NUTS
(1) Shift the transaxle into reverse using the control lever ,+
and select lever. .,./
(2) Install the special tool on the input shaft.

(3) Fit on the spinner handle and bolt.
(4) Tighten the lock nut to specification and then loosen it

completely before tightening it again to the specified
torque.
i;
(5) Punch the lock nut into locked position.

(Punch two places on the lock nut of the input shaft and
one place on the lock nut of the intermediate gear.)

(1) Using the special tool, drive the spring pin into position.
(2) Make sure that the slit in the spring pin is aligned with
the shift rail center line.
Caution A
Do not reuse the spring pin.
MANUAL TRANSAXLE <AWD> - Transaxle Assembly/Backup Light Switch 21-99
13. INSTALLATION OF AIR BREATHER
Apply sealant to the areas with which the air breather
makes contact, and isntall the air breather on the clutch
housing.
or equivalent
sealant

or equivalent
TFM0041
1. INSTALLATION OF REAR COVER

Apply sealant to the rear cover.
Caution
excess or discontinuities.
TFM0035
BACKUP LIGHT SWITCH

INSPECTION
l Actuate the switch and check for continuity with a circuit
tester. If there is no continuity, replace the backup light
switch.
21-100 MANUAL TRANSAXLE <AWD> - Speedometer Gear Assembly
SPEEDOMETER GEAR ASSEMBLY NZlMNAD
Disassembly steps
I. O-ring
l * 2. Spring pin
l 3. Speedometer driven gear
4. Oil seal
5. Sleeve
NOTE
(1) Reverse the disassembly procedures to reassemble
(2) **: Refer to “Service Poirits of Reassembly”.
(3) q : Non-reusable parts.

3. INSTALLATION OF SPEEDOMETER DRIVEN GEAR
Apply a small amount of gear oil to the speedometer driven
gear shaft and insert the gear into position.

lristall the spring pin so that its slit is not in contact with the
gear shaft.
2 q:-*t&f
MANUAL TRANSAXLE <AWD> - 5th Speed Synchronizer Assembly
5TH SPEED SYNCHRONIZER ASSEMBLY WlMHAL
/-- DISASSEMBLY AND REASSEMBLY
. . I
:,
- Disassembly steps TFMOO!56
1. Reverse brake ring

l 2. Synchronizer spring
3. Synchronizer sleeve NOTE
W 4. Synchronizer key (1) Reverse the disassembly procedures to reassemble
I)+ 5. Synchronizer hub (2) *a: Refer to “Service Points of Reassembly”.
INSPECTION
(1) Mate the synchronizer sleeve and hub and check to see if
they slide smoothly without binding.
(2) Make sure that the sleeve is free from damage at its inside
front and rear ends.
NOTE
If replacement is necessary, replace the synchronizer hub
and sleeve as a set.

(1) Make sure that the center protrusion of the synchronizer
key is not worn.
(2) The spring must offer proper tension with no deformation
or damage.
21-102 MANUAL TRANSAXLE <AWD> - 5th Speed Synchronizer Assembly
SERVICE POINTS FOR REASSEMBLY

Oil groove
5. INSTALLATION OF SYNCHRONIZER tjyB.,/4. ,SYN- iic;
CHRONIZER KEY ‘-a-/
Install the synchronizer hub, and key in the directions as
5th
speed + shown.
$2
TFM0046
2. INSTALLATION OF SYNCHRONIZER SPRINGS

Install the synchronizer springs so that its protrusion fits
into the synchronizer key. Make sure that the protrusions in
the front and rear springs do not fit over the same key.
201001a ,
A
MANUAL TRANSAXLE <AWD> - Center Differentid
CENTER DIFFERENTIAL
-4~ DISASSEMBLY AND REASSEMBLY
-
2250015
Disassembly steps
+* l + 1. Taper roller bearing 9. Pinion
l + 2. Bolt 10. Side gear
l *l 3. Taper roller bearing
+ l + 11. Spacer
4. Output flange 12. Center differential case
I)* 5 . S p a c e r
6. Side gear FJ)TEeverse the disassembly procedures to reassemble.
7. Pinion shaft (2) l *: Refer to “Service Points of Disassembly”.
8. Washer (3) l a: Refer to “Service Points of Reassembly”.

1.13. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the taper roller bearings.
Caution
1. Do not reuse the bearing if it has been removed
from the shaft.
bearing as a set.
2210037
21-104 MANUAL TRANSAXLE <AWD> - Center Differential
11. /5. INSTALLATION OF SPACERS I.
(1) Install the spacer, side gear, pinion gear, washer, and z
pinion shaft into the center differential case.
Pinion
gear (2) Select and install the thickest spacer that ensures
smooth and light rotation of the pinion gear when
turned while holding the pinion shaft.
(3) Install the side gear, spacer, and output flange, and
tighten bolts to specification.
(4) Select and install the thickest spacer, that allows
smooth rotation of side gear.
(5) Make sure that the two side gears turn smoothly.
Standard value:
Center differential pinion backlash
0.025 - 0.150 mm (.OOOl - .0060 in.)
3. INSTALLATION OF TAPER ROLLER BEARINGS

Using the special tool, press-fit the taper roller bearing into
MD99881 2
position.
Caution @*
MD998820 Apply the special tool to the inner race only when .___
installing the bearing.
TFM0017
2. INSTALLATION BOLTS
Apply adhesive to the entire thread section of the bolts and
quickly tighten bolts to specification in the order shown.
or equivalent
NOTE
If the bolts are to be reused, completely remove the old
adhesive from the threads.

position.
Caution
Apply the special tool to the inner race only when
installing the bearing. 6
h--
MANUAL TRANSAXLE <AWD> - Front Output Shaft Assembly 9‘1.~105
”
FRONT OUTPUT SHAFT ASSEMBLY ,I N21MKAF
- DISASSEMBLY AND REASSEMBLY ,’

2
Disassembly steps
l *a 1. Taper roller bearing
+* l + 2. Taper roller bearing
3. Front output shaft Reverse the disassembly procedures to reassemble.
4*: Refer to “Service Points of Disassembly”.
l 4: Refer to “Service Points of Reassembly”.
2200075

1./2. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the taper roller bearing.
Caution
1. Do not reuse the bearing if it has been,, removed
from the shaft.
bearing as a set.

Using the special tool, press-fit the taper rbller bearing into
position.
Caution
Apply the special tool to the inner race’ only when

position.
Caution
Apply the special too! to the inner race only when
21-106 MANUAL TRANSAXLE <AWD> - Front Differential
FRONT DIFFERENTIAL NZIMMAG
i;&
95-lOl ft.lbs.
Disassembly steps
l + 1. Bolt l * 9. Spacer :&
2. Differential drive gear 10. Differential case -_-
** l + 3. Ball bearing NOTE
+* l * 4. Lock pin (I) Reverse the disassembly procedures to reassemble
I)+ 5. Pinion shaft (2) C*: Refer to “Service Points of Disassembly”.
l * 6. Pinion (3) l +: Refer to “Service Points of Reassembly”.
I)+ 7. Washer (4) q : Non-reusable parts.
l + 8. Sidegear
160015

Press
Using the special tool, remove the ball bearing.
Caution
Do not reuse the bearing if it has been removed from
the differential case.

Drive out the lock pin from hole A using a punch.
teal case 2200095

MANUAL TRANSAXLE <AWD> - Front Differential 21-107
9. INSTALLATION OF SPACER ! 8. SIDE GEAR / 7.
WASHER / 6. PINION / 5. PINION SHAFT
(1) Fit a spacer on to the back of the side gear and then
install the gear in the differential case.
Caution
When a new side gear is used, use a spacer of
intermediate thickness [0.93-l .OO mm (.0366-
.0394 in.)]
(2) Place a washer at the back of each of the two pinions

and insert the two pinions at the same time, meshing
them with the side gear and rotating them.
(4) Measure the backlash between the side gear and

pinion.
Standard value: 0.025 - 0.150 mm (.OOOl - .0060 in.)
(5) If the backlash is out of specification, disassemble and
reassemble the gears with a new spacer.
Caution
Adjust to provide the same backlash for both side
gears.
160124

Differential case
Align the lock pin hole in the pinion shaft with that in the
Pinion Lot\ pin case and press the lock pin into position.
shaft \-I
\ m Dir&ion of Caution
Installation 1. Do not reuse the lock pin.
2. Make sure that the lock pin head is lower than the
XSide o f lock pi? d, differential case flange surface.
‘$ IS more chamtere
I II 2200096
3. INSTALLATION OF BALL BEARINGS

MD99881 2 Install the ball bearings in both sides of the differential case.
MD99881 9
TFMOOOE
21-108 MANUAL TRANSAXLE <AWD> - Front Differential
Numerals (I) through (8) indicate 1. INSTALLATION OF BOLTS
the bolt tlghtenlng sequence.
Apply adhesive to the entire thread section of the bojts and iii
quickly tighten bolts to specification in the order shown.
-2
or equivalent
Caution
If the bolts are to be reused, completely remove the old
adhesive from the threads.
,-’ DISASSEMBLY AND REASSEMBLY
I
Disassembly steps
1. 3rd-4th speed shift fork
2. 1 st-2nd speed shift fork
3. 1 st-2nd speed shift rail
4. 5th-Rev. speed shift rail
l 4 5. interlock plunger
6. 3rd-4th speed shift rail NOTE
7. Reverse shift lug (1) Reverse the disassembly procedures to reassemble.
(2) l 4: Refer to “Service Points of Reassembly”.
I- -
210027

5. INSTALLATION OF INTERLOCK PLUNGER
Fit the interlock plunger into the position shown in 3rd-4th
speed shift rail.
\
3rd-4th speed shift rail 201088
21-I 10 MANUAL TRANSAXLE <AWD> - Intermediate Gear Assembly
NPlMJAR
INTERMEDIATE GEAR ASSEMBLY
j”r:
Disassembly steps
** 1. Snap ring
l * l + 2. Taper roller bearing
l * 3. Bearing sleeve
l * 4. 1 st speed gear
5. Needle bearing
l a 6. Synchronizer ring
l + 7. Synchronizer spring
l a 8. 1 st-2nd speed synchronizer sleeve
l * 9. Synchronizer key
w l a IO. 1 st-2nd speed synchronizer hub
l * II. Synchronizer ring NOTE
a* 12. 2nd speed gear (I) Reverse the disassembly procedures to reassemble. A
13. Needle bearing (2) +*: Refer to “Service Points of Disassembly”. h..
l * l * 14. Taper roller bearing (3) l C: Refer to “Service Points of Reassembly”.
15. Intermediate gear (4) q : Non-reusable parts.
MANUAL TRANSAXLE <AWD> - intermediate Gear Assembly 21’-111
MD998801 2. REMOVAL OF TAPER ROLLER BEARING / 4. IST SPEED
GEAR
I
Using the special tool, remove the taper roller bearing, the
1st speed gear, and the bearing sleeve.
Caution
from the shaft.
bearing as a set.
10. REMOVAL OF IST-2ND SPEED SYNCHRONIZER HUB /

12. 2ND SPEED GEAR
Using the special tool, remove the lst-2nd speed synchro-
nizer assembly and 2nd speed gear.
70106:

Caution
from the shaft.
bearing as a set.
INSPECTION
INTERMEDIATE GEAR
l Check the outer surface of the intermediate gear where the
needle bearing is mounted for damage; abnormal wear, and
seizure (portion @I.
l Check splines for damage and wear.
Sphnes
201065
21-112 MANUAL TRANSAXLE <AWD> - Intermediate Gear Assembly
NEEDLE BEARING
l Mate the needle bearing with the shaft or bearing sleeve
and gear, and check to see if rotation is smooth with no ++
binding, noise, or play.
l Check the needle bearing cage for possible deformation.
201051
SYNCHRONIZER RING
Damage, breakage I
peeling.
-FM0119

check clearance “A”. Replace if the measurement is below
the limit.
Limit: 0.5 mm (.020 in.)
,-W
I-.
Synchronizer ring Gear FM0117

l Mate the synchronizer sleeve with the hub and check to
see if they slide smoothly.
l Check to see if the sleeve is free from damage at its inside
l Check the hub front and rear end faces (in contact with
each speed gear) for wear.
Caution
When replacement is necessary, replace the synchro-
nizer hub and sleeve as a set.

l Check the synchronizer key center protrusion for wear.
l Check the spring for proper tension, possible deformation
and breakage.
A
MANUAL TRANSAXLE <AWD> - Intermediate Gear Assemblv 21-113
SPEED GEARS
l Check the bevel and clutch gear teeth for damage and
wear.
l Check the synchronizer cone for rough surface, damage,
and wear.
and wear.

D998350 Using the special tool, press-fit the taper roller bearing over
the intermediate gear.
Caution
Apply pressure with the special tool only to the inner
race when installing the bearing.
21002:
11. / 6. INSTALLATION OF SYNCHRONIZER RING

Note the identification mark made on the 1st speed
synchronizer ring.
r
$J$ch housing 10. INSTALLATION OF lST-2ND SYNCHRONIZER HUB / 9.
c SYNCHRONIZER KEY / 8. lST-2ND SYNCHRONIZER
SLEEVE / 7. SYNCHRONIZER SPRING
(1) Mate the 1 st-2nd speed synchronizer hub and sleeve as
shown.
(2) Install the synchronizer spring so that its protrusion fits

into the groove in synchronizer key.
Caution-
Make sure that the protrusions in the front and rear
springs are not in the groove of the same key.
-. prorruslon
NOTE
A synchronizer spring different from the one shown in
the figure may be used but the explanation is the same.
Sprin
protrusion
21-I 14 MANUAL TRANSAXLE <AWD> - Intermediate Gear Assembly
(3) Using the special tool, press-fit the lst-2nd speed
synchronizer assembly over the intermediate gear.
fk
Caution
1. When installing the synchronizer assembly, -i
make sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring.
2. After installing the synchronizer assembly,
check to see if the 3rd speed gear rotates
smoothly.
TFM0023

Using the special tool, press-fit the 1st speed gear and
, MD998350
bearing sleeve.
4

Using the special tool, press-fit the taper roller bearing.
Caution
Apply pressure with the special tool only to the inner
race when installing the bearing.

Select and install the snap ring so that the end play of the
intermediate shaft is up to specification.
Standard value: 0.01-0.11 mm (.0004-.OO43 in.)
MANUAL TRANSAXLE <AWD> - Input Shaft Assembly 21-115
INPUT SHAFT ASSEMBLY NZlMlASa
-- DISASSEMBLY AND REASSEMBLY
18
Disassembly steps
+e I)+ I. Taper roller bearing 14. Synchronizer ring
~~ I)4 2. Bearing sleeve 4* 15. 3rd speed gear
*4 3. Snap ring ++ 16. Snap ring
+e I)+ 4. Taper roller bearing +* 17. Cone spring
5. 4th speed gear +4 18. Sub gear
6. Needle bearing 19. Needle bearing
I)+ 7. Bearing sleeve 20. Input shaft
8. Synchronizer ring
I)+ 9. 3rd-4th speed synchronizer assembly NOTE
++ IO. Synchronizer spring (1) Reverse the disassembly procedures to reassemble.
11. 3rd4th speed synchronizer assembly (2) +e : Refer to “Service Points of Disassembly”.
12. Synchronizer key (3) +* : Refer to “Service Points of Reassembly”.
13. 3rd-4th speed synchronizer hub (4) m : Non-reusable parts.
21-116 MANUAL TRANSAXLE <AWD> - Input Shaft Assembly
Using the special tool, remove the front bearing.
c

illustrated.

Using the special tool, remove the bearing sleeve and rear
bearing.
15. REMOVAL OF 3RD SPEED GEAR ;;c.
Using the special tool, remove the bearing sleeve, 3rd-4th i”-
speed synchronizer assembly, and 3rd speed gear.
INSPECTION
INPUT SHAFT
l Check the outer surface of the input shaft where the needle
bearing is mounted for damage, abnormal wear, and
seizure (portion &I).
h
4
MANUAL TRANSAXLE <AWD> - Input Shaft Assemblv 214 IO
NEEDLE BEARING
_. l Mate the needle bearing with the shaft or bearing sleeve
and gear, and check to see if rotation is smooth with no
binding, noise, or play.
l Check the needle bearing cage for possible deformation.
Damage, breakage
SYNCHRONIZER RING
peeling.
TFMO119

check clearance “A”. Replace if the clearance is below the
limit.
Limit: 0.5 mm (.020 in.)
Synchronizer ring Gear

TFM0117

l Mate the synchronizer sleeve with the hub and check to
see if they slide smoothly.
l Check to see if the sleeve is free from damage at its inside
l Check the hub front and rear end faces (in contact with
each speed gear) for wear.
Caution
When replacement is necessary, replace the synchro-
nizer hub and sleeve as a set.
20104~ 1

l Check the synchronizer key center protrusion for wear.
l Check the spring for proper tension, possible deformation
and breakage.
201045
MANUAL TRANSAXLE <AWD> - Input Shaft Assembly
SPEED GEARS
l Check the bevel and clutch gear teeth for damage and .6
wear.
l Check the synchronizer cone for rough surfaces, damage, -‘
and wear.
and wear.
lama
vear
SERVICE POlNTS OF REASSEMBLY

18. INSTALLATION OF SUB GEAR/17. CONE SPRING/
16. SNAP RING
Install the sub gear and cone spring to 3rd speed gear, and
then install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing in
the correct direction.
210018
10. INSTALLATION OF SYNCHRONIZER SPRINGS

Key (1) Install the synchronizer spring so that its protrusion fits
Spring into the groove in synchronizer key. Make sure that the
protrusion protrusions in the front and rear springs are not in the in,
groove of the same key.
201001::

ASSEMBLY
the hub end.
NOTE
round indentation is made to facilitate pressing in.
(2) Using the special tools, press-fit the 3rd-4th speed
synchronizer assembly over the input shaft.
Caution
1. When installing the synchronizer assembly,
make sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring. h
2. After installing the synchronizer assembly, --
check to see if the 3rd speed gear rotates
smoothly.
TFM0023
MANUAL TRANSAXLE <AWD> - Input Shaft Assembly 21-l 19
Using the special tool, press-fit the bearing sleeve.

Using the special tools, press-fit the bearing over the input
shaft.
Caution
Apply the special tool to the inner race only when

(1) Select the thickest snap ring that fits in the snap ring
groove.
(2) Using the special tool, fit the snap ring to the input
shaft.
MD998808-01
(Outer) NOTE
MD998808-01
(I) Do not reuse the snap ring.
(2) The use of snap ring plier can cause the snap ring to
expand too much, making correct installation of the
sleeve difficult.
2150016
21-120 MANUAL TRANSAXLE <AWD> - Input Shaft Assembly
Using the special tool, install the bearing sleeve over the ,k
input shaft.
-‘d ’
Caution
When the sleeve has been press-fitted over the input
shaft, make sure that the sleeve flange is in tight
contact with the bearing.
2150017

Using the special tool, press-fit the ball bearing over the
input shaft.
h
MANUAL TRANSAXLE <AWD> - Clutch Housing Assembly 21-121
CLUTCH HOUSING ASSEMBLY NZlMPAH
15-22 Nm
15 ft.lbs.
2 0 - 27 Nm
1 5 - 19 ft.lbs.
18'
2210128
Disassembly steps
I, Bolt l * 15. Oil seal
2. Select lever assembly *I) l * 16. Needle bearing
3. Select lever shoe a* l + 17. Needle bearing
4. Interlock plate bolt 18. Clutch housing
5. Gasket 19. Pin
+* WC 6. Lock pin 20. Return spring
l * l * 7. Spring pin 21. Stopper plate
8. Neutral return spring 22. Spring pin
9. Stopper body NOTE
10. Control finger (1) Reverse the disassembly procedures to reassemble.
11, Interlock plate (2) l +: Refer to “Service Points of Disassembly”.
12. Neutral return spring assembly (3) l C: Refer to “Service Points of Reassembly”.
13. Control shaft (4) a: Non-reusable parts.
14. Control shaft boot
21-122 MANUAL TRANSAXLE <AWD> - Clutch Housing Assembly
Drive out the lock pin from the control finger using the
special tool or a pin punch.
Caution
When removing the lock pin, turn the control lever to a
position so that the lock pin will not contact the clutch
housing.

Using the special tool or a pin punch, drive out the spring
pin from the stopper body.
Caution
When removing the spring pin, pull the control shaft in
the direction shown so that the spring pin will not
contact the clutch housing.
16.7 17. REMOVAL OF NEEDLE BEARING

Drive out the needle bearing using a socket wrench.
13mm
socket wrench
A SERVICE POINTS OF REASSEMBLY

17. / 16. INSTALLATION OF NEEDLE BEARINGS
(1) Using a socket wrench, press-fit the needle bearing
flush with surface A in the clutch housing.
(2) Make sure that the side of the bearing with a stamped
type number faces surface A.
Needle bearing
II
201084
MANUAL TRANSAXLE <AWD> - Clutch Housing Assembly 21-123

Using a socket wrench, install the control shaft oil seal.
7. INSTALLATION OF SPRING PIN / 6. LOCK PIN

Using the special tool, drive a new spring pin and lock pin
into position.
Caution
1. Do not reuse the spring pin or lock pin.
2. Install the spring pin so that its slit will be at right
angles to the control shaft centerline.
21-124 MANUAL TRANSAXLE <AWD> - Transfer Assembly
TRANSFER ASSEMBLY
8-10Nm
6-7ft.‘bs.Y
15-22Nm
2210130
Disassembly steps
1. Cover
2. Cover gasket
l * 3. Extension housing assembly
l * 4. Transfer case sub assembly NOTE
l * 5. Spacer (I ) Reverse the disassembly proceduresto reassemble
6. O-ring (2) l +: Refer to “Service Points of Reassembly”.
l * 7. Transfer case adapter sub assembly (3) a: Non-reusable parts.
MANUAL TRANSAXLE <AWD> - Transfer Assembly
7 SERVICE POINTS OF REASSEMBLY
P
7. INSTALLATION OF TRANSFER CASE ADAPTER SUB-
ASSEMBLY
Using a brush, apply a thin even coat of machine blue or
minium to both tooth surfaces of the driven bevel gear.
Install the spacer which has been used so far.
2210050
4. INSTALLATION OF TRANSFER CASE SUBASSEMBLY

(1) Tighten the transfer case adapter subassembly on the
transfer case subassembly to the specified torque.
MB990900 (2) Using the special tool, turn the drive bevel gear shaft
one turn each in the direction of normal and reverse
rotation.
Caution
Do not rotate the drive bevel gear shaft more than
one turn as it cause a blurred tooth contact pattern.
TFMOOIP
(3) Make sure that the contact pattern of the driven bevel
gear teeth is correct.
NOTE
See Tooth Contact Adjustment Procedure on next page
for the standard tooth contact pattern.
21-126 MANUAL TRANSAXLE <AWD> - Transfer Assembly
(4) Check to see if the backlash between the drive and
driven bevel gears is up to specification.
Standard value
Bevel gear set backlash:
0.08-0.13 mm (.0031-.005 in.)
3. INSTALLATION OF EXTENSION HOUSING

Apply sealant to the flange surface of the adapter and install
the housing.
Caution
Squeeze out the sealant from the tube uniformly
without excess or discontinuities.
TOOTH CONTACT ADJUSTMENT PROCEDURE

1. Standard tooth contact pattern
A: Small end
B: Drive side tooth surface
(The side receiving force in forward motion)
C: Big end
D: Coast side tooth surface
(The side receiving force in reverse motion)
2210061
2. Tooth contact pattern when driven bevel gear is too

high
Possible cause:
The driven bevel gear is too close to the drive bevel gear.
2210092
Remedy:
Use a thicker spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is further away
from the drive bevel gear.
2210093
MANUAL TRANSAXLE <AWD> - Transfer Assembly
low
Possible cause: ,
The driven bevel gear is further away from the drive bevel
gear than necessary.
2210094
Remedy:
Use a thinner spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is closer to the
drive bevel gear.
2210095
NOTE
(1) If correct tooth contact cannot be obtained by replace-
ment of spacer for adjusting driven bevel gear mount,
Spacer for change the spacers for adjustment of drive bevel gear
adjusting drive
bevel gear mount Spacer for preload and drive bevel gear mount adjustment to those
I adjusting drive of appropriate thickness as described below and adjust
bevel gear preload the tooth contact again.
l If the driven bevel gear height is still too small when
the thinnest spacer for driven bevel gear mount
adjustment [0.13 mm (.005 in.)] is used;
Change the spacer for drive bevel gear mount
adjustment to the next thicker one and change the
Spacer for spacer for drive bevel gear preload adjustment to
adjusting the next thinner one.
driven bevel l If the driven bevel gear height is still too large when
gear mount
the thickest spacer for driven bevel gear mount
adjustment [0.52 mm (020 in.)] is used;
Spacer for Change the spacer for drive bevel gear mount
adjusting adjustment to the next thinner one and change the
driven bevel
gear preloac spacer for drive bevel gear preload adjustment to
the next thicker one.
Repeat above steps until standard tooth contact
pattern is obtained.
(2) If the tooth contact pattern cannot be brought close ,to
the standard pattern by the adjustment described
above, replace the drive bevel gear and driven bevel
gear as a set and adjust the tooth contact again.
21-128 MANUAL TRANSAXLE <AWD> - Extension Housing Assembly
EXTENSION HOUSING ASSEMBLY N21MTAA
TFM0039
Disassembly steps
6+ 1. Air breather NOTE
2. Dust seal guard (I) Reverse the disassembly procedures to reassemble.
I)+ 3. Oil seal (2) l *: Refer to “Service Points of Reassembly”.
4. Extension housing (3) q : Non-reusable parts.

Using the special tool, install the oil seal.
.

Apply sealant to the air breather port and fit the air breather
in position.
or equivalent
MANUAL TRANSAXLE <AWD> - Transfer Case Sub Assembly 21;129
TRANSFER CASE SUB ASSEMBLY N21MUAA
- DISASSEMBLY AND REASSEMBLY
I-
2210079
‘35-42Nm
26 - 30 ft.lbs.
Disassembly steps
I. Transfer cover
2. O-ring
l a 3. Spacer
4. Outer race
5. Drive bevel gear assembly
6. Outer race
*a 7. Spacer
l * 8. Oil seal
9. Transfer case
- NOTE
(1) Reverse the disassembly procedures to reassemble
(2) *a: Refer to “Service Points of Reassembly”.
(3) q : Non-reusable parts.
21-130 MANUAL TRANSAXLE <AWD> - Transfer Case Sub Assembly
8. INSTALLATION OF OIL SEAL jP,
Using the special tool, install the oil seaII. . -6
Install the spacer which has been used so far
Install the spacer which has been used so far
INSPECTION
DRIVE BEVEL GEAR ASSEMBLY
Using the special tools, check to see if the turning drive torque
of the drive bevel gear is up to specification.
Standard value: 1.7 - 2.5 Nm (1.23 - 1.81 ft.lbs.)
Caution
1. If the turning drive torque is out of specification, adjust
by using adjusting spacers.
2. Select spacers of nearly same thickness on both sides.
h
MANUAL TRANSAXLE <AWD> - Transfer Case Adapter Sub Assembly 2143’1
TRANSFER CASE ADAPTER SUB ASSEMBLY N2lhlVAS
1’” DISASSEMBLY AND REASSEMBLY
I 2210133
140 - 160 Nm
102-115ft.lbs.
Disassembly steps
w l a 1. Locknut
a* 2. Driven bevel gear assembly
l * 3. Taper roller bearing
l * 4. Spacer NOTE
5. Collar (1) Reverse the disassembly procedures to reassemble.
(2) +*: Refer to “Service Points of Disassembly”.
l * 6. Outer race
.- (3) *+: Refer to “Service Points of Reassembly”.
l * 7. Outer race (4) q : Non-reusable parts.
8. Transfer case adapter
21-132 MANUAL TRANSAXLE <AWD> - Transfer Case Adapter Sub Assembly

1. REMOVAL OF LOCK NUT
(1) Unstake the lock nut.
(2) Remove the driven bevel gear’s lock nut by using the
special tool.
2. REMOVAL OF DRIVEN BEVEL GEAR ASSEMBLY

Using a press, remove the driven bevel ‘gear assembly.
6.17. REMOVAL OF OUTER RACE

Apply a screwdriver to the outer race and tap it to remove
the outer race.

MANUAL TRANSAXLE <AWD> - Transfer Case Adapter Sub Assembly ml33
BMD9988121 11 Using the special tool, install the taper roller bea&.
\ z, ‘.
MDgg881 4 --I-
1. INSTALLATION OF LOCK NUT

(1) Tighten the driven bevel gear’s lock nut at the specified
torque by using the special tool.
(2) Stake the lock nut at two places for locking
INSPECTION
DRIVEN BEVEL GEAR ASSEMBLY
Using the special tool, check to see if the turning drive torque
of the driven bevel gear is up to specification.
Standard value: 1.0 - 1.7 Nm (0.72 - 1.23 ftlbs.)
Caution
If the turning drive torque is out of specification, adjust
with the adjusting spacer.
2210141 1
21-134 MANUAL TRANSAXLE <AWD> - Drive Bevel Gear Assembly
DRIVE BEVEL GEAR ASSEMBLY NZlMWAA
Disassembly steps TFM0053
4~ WI 1. Taper roller bearing NOTE

+* l 4 2. Taper roller bearing (I) Reverse the disassembly procedures to reassemble.
l * 3. Drive bevel gear (2) **: Refer to “Service Points of Disassembly”.
4. Drive bevel gear shaft (3) *a: Refer to “Service Points of Reassembly”.

1.12. REMOVAL OF TAPER ROLLER BEARING
22100851
MANUAL TRANSAXLE <AWD> - Drive Bevel Gear Assembly 2f-135
3. REMOVAL OF DRIVE BEVEL GEAR
Using the special tool, remgve the drive bevel gear.
v 2210087

2.11. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, install the taper roller bearing.
21-136 MANUAL TRANSAXLE <AWD> - Driven Bevel Gear Assembly
DRIVEN BEVEL GEAR ASSEMBLY
Disassembly steps
a* I)* 1. Taper roller bearing
2. Driven bevel gear
NOTE
(I) Reverse the disassembly procedures to reassemble, 2210143
(2) +*: Refer to “Service Points of Disassembly”.
(3) l +: Refer to “Service Points of Reassembly”.

998801 A
2210144

Using the collar, install the taper roller bearing.
AUTOMATIC TRANSAXLE - General Information 21437
AUTOMATIC TRANSAXLE
_,s
GENERAL INFORMATION NZlBABTa
Cautionary points during disassembly and Do not reuse gaskets, oil seals and rubber parts.
assembly of the transaxle Replace them with new ones at every reassem-
Because the automatic transaxle is composed of bly. O-ring of oil level gauge need not be
component parts of an especially high degree of replaced.
precision, these parts should be very carefully Do not use grease other than petrolatum jelly.
handled during disassembly and assembly so as Apply ATF to friction element, rotating parts, and
not to scar or scratch them. sliding parts before installation.
A rubber mat should be placed on the work- New clutch disc should be immersed in ATF for
bench, and it should always be kept clean. more than two hours before installation.
During disassembly, cloth gloves or shop towels Do not apply sealer or adhesive to gaskets.
should not be used. When bushing must be replaced, replace
If such items must be used, use articles made of assembly which includes it.
nylon, or use paper towels. If the transaxle main unit is damaged, also
All disassemblyed parts must be thoroughly disassembly and clean the cooler system.
cleaned. In order to prevent a sudden start as a result of
Metal parts may be cleaned with ordinary accidental misoperation of the select lever, this
detergents, but must be thoroughly air dried. model is provided with the automatic-transaxle
Clean the clutch disc, resin thrust plate and safety-lock system.
rubber parts by using ATF (automatic transmis-
sion fluid), being very careful that dust, dirt, etc.
do not adhere.
21-138 AUTOMATIC TRANSAXLE - General Information
<F4A22>
Pulse generator A
Transfer idler gear
Torque converter
Transfer driven gear

Differential
nerator B
TFAO480
AUTOMATIC TRANSAXLE - General Information
<F4A33>
Transfer
v/nwerse idler gear
ke
Planetary
gear set !
Torque
converter -
Transfer
drive gear
End
- clutch
Transfek shaft
. Differential
TFAOl 01
:W4A33>
Transfer
2%
Kickdown
band --/
Oil pump Rear
Front clutch
\ clutch I I
:h
Torque
converter
Rear output
shaft
Transfer \
Front
output shaft
Differential
A
-’
TFA0102
AUTOMATIC TRANSAXLE - General Information 21-141
<F4A22 - Neutral>
Kickdown servo
Low-reverse
brake
Front clutch Rear clutch End clutch
Ex
control solenoid
valve
To lubrvzatlon
(front) -
T o lubrlcatlon +=
(rear)
Shift control
valve
~~&-----~ Manual 1
(L- “,::mr J
1 011 p u m p suction pressure 0 Damper clutch pressure

m Line pressure
Damper clutch control solenoid
Torque converter and lubncatlon n M o d u l a t e d line p r e s s u r e valve pressure
lm
0 pMSS”V2
Pressure control solenoid
= Reducing p r e s s u r e I valve pressure
TFA0070
<WA22 - Parking>
Klckdown servo
Low-reverse
-,
brake
Front clutch End clutch
Damper clutch
control valve
Damper clutch
control solenord
To lubrication +_
ifront)
T o lubncatlon CJ
Irear)
I I .“‘-- - Shaft control
114 !!. B ii I II II II/l II II .
Tl Pressure control
Pressure
\ \, Yal”e Em
I Line pressure 0 011 p u m p suctton pressure m Damper clutch pressure
xque converter and lubrlcatlon Damper clutch control solenoid

0 M o d u l a t e d line p r e s s u r e
essure valve pressure
Reducing pressure Pressure control solenoid

-I valve pressure
TFA0071
<F4A22- Drive-Stopping >
Kickdown servo
Toraue converter
c -r
Front clutc End clutch
/
L OFF
Ex
Damper clutch
control solenoid
valve
To lubrlcatlon c
(front)
To lubrlcatlon c
(rear)
Pressure
011 pan
= Line p r e s s u r e 1 011 p u m p suction pressure m Damper clutch pressure
m T o r q u e c o n v e r t e r ana lubr!catlon Modulated lane pressure Damper clutch control solenoid

pressure valve pressure
m Reducing p r e s s u r e Pressure control solenoid

L-I valve pressure
) Drive (Stopping) (
TFA024 2
(F4A22 - Drive-First>
Klckdawn servo
Torn!w converter
Low reverse
L.-J ^
F
12
w$=
control val
OFF
R
exhaust valve
En
Damper clutch
control soleno
valve
To lubncatlon c
(front)
T o lubrlcatlon c=
(rear)
/
N-D control
valve
m Line p r e s s u r e 0 011 p u m p s u c t i o n p r e s s u r e amper clutch pressure
‘vque converter and lubncatlon 0 M o d u l a t e d line p r e s s u r e uamper clutch control solenoid

essure valve pressure
, .Lduclng pressure I valve pressure
Drive (First)
TFA0072
<F4A22 - Drive-Second>
Klckdown servo
Torque converter
Low reverse
brake
+
Damper cluF:h
control solenoid
valve
T o lubrication c
5%
(front)
T o lubrlcatlon cz
(rear)
N-D control
valve
I,,--.- - I Pressure control

n I valve
A hii
e
Pressure
1 Line relief
i ; valve
EX
011 pan
= Line p r e s s u r e 011 p u m p suction pressure Damper clutch pressure

ml
T o r q u e converter and lubrlcatlon Damper clutch control solenoid

M o d u l a t e d lane pressure
0 pressure 1 valve pressure

m Redumg pressure
valve pressure
1 Drive (Second) 1
TFA0073
cF4A22 - Drive-Third>
Klckdown servo
Torque converter
-,
tnd clutch
exhaust valve
I@4
Damper clut?
control solenord
valve
To lubrication
(front) c
To lubncatlon cLI clutch
(rear)
+ I
valve ” - “Al” H i I
&len;valve 9 1 1
Shift control Ex
solenord
valve “B”
m Line pressure 0 011 p u m p suctron p r e s s u r e m Damper clutch pressure
- Torque converter and lubricatron Damper clutch control solenord

n M o d u l a t e d line p r e s s u r e
jressure valve pressure
,ledwng pressure Pressure control solenoid

7 valve pressure
TFA0074
<F4A22 - Drive-Fourth>
Klckdown servo
Torque converter
Low~reverse
5-l brake -,
\ Front clutch Rear clutch End clutch I
4
7-l’” exhaust valve
Damper clut
control soler
valve
;k$icatton c
T o lubrlcatlon c=
(rear)
1 ) Shift c o n t r o l ix
valve
v- 1.
I ) I -
Pressure control
x-w 2 011
pump
11
E Line reltef
: : valve
EX
011 pan
unit
m Line p r e s s u r e 0 011 p u m p s u c t i o n p r e s s u r e m Damper clutch pressure
Torque converter and lubrication Damper clutch control solenoid

n M o d u l a t e d line p r e s s u r e
pressure valve pressure

ve pressure
TFA0075
<F4A22 - Lock-up>
Klckdown servo
Low-reverse
,-.. “_.”
Frnnt rl,,trh -- ---
Rear rllltrh brake
Es3 - I
Damper clutc
control solenc
valve l-2 shift
:fool,u$rlcatlon c valve
ux
r
I orque
converter
control
valve $
r
valve “B”
Shift control
valve
Pressure control
1’1 -
1 filter
011 pan
m Lme p r e s s u r e 0 011 p u m p suction p r e s s u r e = Damper clutch pressure
rl
Damper clutch control solenoid
Torque converter and lubncatlon 0 Modulated lme p r e s s u r e I valve pressure
pressure
Reducing pressure valve pressure
TFA0076
<F4A22 - Reverse>
Kxkdown servo
LOW-WWWZ
bl
OFF
exhaust valve
I”’
1:: l-i
z
EX
Damper clutch
control solenoidr
valve
T o lubncatlon c
(front) .
nd c
P
h
alve
-.
I
r
F,,$Rl
*
S heft control E N-D control

S olenold
” alve “B”
Shift control
I Pressure control
I ’ PRND2L
I! valve
I’ F
1 011ftlter J
011 pa”
m Line p r e s s u r e 0 011 p u m p suction pressure Damper clutch pressure

m
Torque converter and lubncatlon Damper clutch control solenoid
0 M o d u l a t e d line p r e s s u r e
pressure m valve pressure
m Reducing p r e s s u r e Pressure control solenoid

0 valve pressure
I Reverse I
TFA0077
cF4A33.W4A33-Neutral>
:r Kickdown servo
Low-reverse
brake
T o lubrlcal
(front)
'-I' II
i ii’\\ Ex ii Rear clutch
exhaust valve
conierter
a
Ex R e d u c i n g
valve q
j clutch
control
valve
E"
Shift control
solenoid
v a l v e “B”
L 011 filter J
011 pan
Lme pressure 011 p u m p suction pressure

0
Torque converter and lubrlcatlon

ml 0 M o d u l a t e d lme p r e s s u r e
pressure

Redumg pressure
0 valve Dressure
Neutral
TFAOO78
Klckdown servo
Torque converter Low-reverse
DraKe
Front clutch Rear clutch \: End clutch
F F
Iii!
IIII
P
/
1
18
!P
/
To lubrication
-- (rear) 4-m tX II
I / ‘-‘Shift control
Torque
converter
control
valve ~0
IF=
EK
valve
ure control
Pressure
control
solenoid
alve
Z5ll
011 pan
’ ‘-e pressure 011 p u m p suction pressure
que c o n v e r t e r ano mmcatlon M o d u l a t e d lme pressure

rlrSSure
m Reducing pressure I valve pressure
Parking
TFA0079
<F4A33.W4A33-Drive-Stopping>
Klckdown servo
Torque converter
Low-reverse
brake
T o lubncatlon
2-3 and 4-3
l-2sh1ft I 11
-_
h
\E . Reducmg
Torque
converter
control
valve
N-D control
essure control
live
n Pre%%lre
II I I !! n i” control
Fl - - solmold
valve
Transaxle
Oil pan control ““lt
0 Lane p r e s s u r e 011 pump suction pressure
Torque converter and lubrlcatm

ssure I M o d u l a t e d Ime pressure

juclng pressure El v a l v e oressure
Drive (Stopping)
TFA0080
AUTOMATIC TRANSAXLE - General Information 21453
Ktckdown servo
Torque converter
Low-rever se
brake
Front clutch Rear clutch
‘-2 sh’+f [;
valve
\I
T o lubn zatlon
(rear) 4-Z & Reducmg
Torque
converter ;\
control
valve
Oil pan
II 1-0 pressure 0 011 pump suctm p r e s s u r e
ue c o n v e r t e r and lubrfcataon 0 Modulated lme p r e s s u r e

r.-z~re
m Reducmg p r e s s u r e 0 valve pressure
TFA0081
< F4A33.W4A33- Drive-Second >
Kickdown servo
Torque converter
Front clutch Rear c
I
.
II
T o lubrlcatlon
( f r o n t ) ,d
T o lubncatlon
(rear) += h
Torque
converter
control
valve
, ,,,.--- III il
.O-
I I Pressure
valve
control
f-k3 j
.I 1311 filter
011 pan
m 011 p u m p suction pressure
jue c o n v e r t e r and lubrmtlon

0 M o d u l a t e d Ime pressure
isure
Pressure control solenold
m Reducing pre%urP valve pressure
TFAOOBP
<F4A33.W4A33-Drive-Third>
Klckdown servo
Torque converter
LOW-WW?WZ
brake
To lubncatlon
To lubrl--- --
(rear)
Torque
converter
control
valve p
4-h 1:
exhaust valve J,,,
81
End clutch
‘valve
valve “5”
,-----I . -
ve
m Lone pressure 0 011 Pump suction pressure
Torque converter and lubncatmn 0 Modulated lme pressure

pressure
m Reducmg pressure n Pressure control solenoid

valve pressure
I Drive (Third) I
TFA0083
<F4A33.W4A33 - Drive-Fourth >
Kickdown servo
Low reverse
brake
Y
To lubrvzatlon
( f r o n t ) cz
To lubnc
(rear)
Torque
converter
control
valve
P
\
control
Pressure control
valve
-
a
I
L Oil filter
Oil pan
m Lone pressure m 011 pump swtlon pressure
ue converter and lubncatlon n Modulated ltne pressure

sure
1 Redumg pressure
n Pressure control solenoid
valve pressure
1 Drive (Fourth)
TFA0084
-___ ___-_..

<F4A33.W4A33-Lock-up>
Klckdown servo
? converter
Low reverse
brake
Front clutch Rear clutch zrlutch
-PY
To lubrlcatlon
7lo,,l;bricatlon
-2iiiiia h
--
Torque
converter
control
valve
*
F
Ex
It i II I
EX
II v a l v e tl Shift control
valve I
control
III . II I valve
ure control
Pressure
control
solenoid
I valve
\I
i i Lme relief
”
Ex
valve
Oil Dan
Ltne pressure 011 pump suction pressure
Torque converter and lubrlcatloy n Modulated lme pressure

0 pressure
Reducmg pressure n Pressure control solenoid

valve pressure
TFA0085
Torque converter Klckdown servo

Low-reverse
brake --
rant clutch Rear clutch End&&h
To lubrlcatlon
(front) c
(r
clutch
T,,,,, e
converter
valve “8”
Shift control
valve
a+
N-R control 1
II
Fi
Z :
Lme relief
valve
1 011 filter J
011 pan
Lme pressure pyj 011 pump Suction pressure
Torque convcrtcr and lubrlcatlon

I pressure 0 Modulated Ime pressure
1 Reducmg pressure Pressure control solenoid

0 valve pressure
TFA0066
AUTOMATIC TRANSAXLE - Specifications
SPECIFICATIONS
-+ GENERAL SPECIFICATIONS l@lCA.C
Items 1.8L Engine 2.0L DOHC Engine 2.0L DOHC 2.0 DQHC
Turbo Engine T”‘pJyine .
F4A22-2-M PD F4A22-2-M PD 1 F4A33-U P61 W4A33-1 -U P6
Type Full automatic Full automatic Full automatic Full automatic
4 speed transaxle 4 speed transaxle 4 speed transaxle 4 speed transaxle
Torque converter
Type 3 element with 3 element with 3 element with 3 element with
damper clutch damper clutch damper clutch damper clfi&h
Engine stall speed 1,800-2,800 rpm 1,800-2,800 rpm 1,800-2,800 rpm 1,800-2,806 ipm
Stall speed ratio 2.05 1.90 1.74 1.74 *,
Transaxle
Type Electronically Electronically Electrbnically Electrotiically
controlled 4 speed controlled 4 speed controlled 4 speed controlled,i4’ speed
full automatic full automatic full automatic full automatic
Gear ratio
First 2.846 2.846 2.551 2.551
Second 1.581 1.581 1.488 1.488 f *r c
Third 1 .ooo 1 .ooo 1 .ooo 1 .ooo

Fourth 0.685 0.685 0.685 0.685
Reverse 2.176 2.176 2.176 2.176
Final gear ratio 4.007 4.007 4.376 4.42’2 ” ”
Speedometer gear ratio 36129 36129 36129 36129 *
[drive/driven) ‘, !
Transaxle
Standard value
Transfer driven gear preload (Center differential case
p r e l o a d ) <F4A33. W4A33> mm (in.) 0.075-0.135 (.0030-.0053)
Transfer shaft end play <F4A22> mm (in.) O-0.025 (O-.001 0)
Low reverse brake end play mm (in.) 1.0-l .2 (.039-,047)
Input shaft end play mm (in.) 0.3-l .o (.012-.039) .,
,*, ,_ ,”
Differential case end play <F4A22> mm (in.) O-O.1 5 (O-.006)
1.
Differential case preload <F4A33> mm (in.) 0.075-O. 135 (.0030- .0053)
Differential case end play <W4A33> mm (in.) 0.045-0.165 (.0017-.0064)
Differential gear and pinion backlash mm (in.) 0.025-0.150 (.OOlO-.0059) ., ‘.a .;.; ‘>
Oil pump side clearance o.03-o.05 (~oo12-~o(j~o’) ” i.u:-., ‘~
mm (in.)
Output flange bearing play <F4A22> mm (in.) O-0.06 (O-.0024)
21-160 AUTOMATIC TRANSAXLE - Specifidons
Output flange bearing end play <F4A33, W4A33> mm (in.) o-0.09 (d-.0035)
; . ,
.”
i f 1
:
, ,i’
,li
Front clutch end play <F4A22> mm, (in.) 0.7-0.9 (.028-.035)
Rear clutch end play <F4A22> mm (in.) 0.4-0.6 (.016-.024)
End clutch end play <F4A22> mm (in.) 0.4-0.65 (.016-.026)
Front clutch end play <F4A33, W4A33> mm (in.) 0.8-I .O (.032-.039)
Rear clutch end play <F4A33, W4A33> mm (in.) 1.0-I .2 (.039-.047)
End clutch end play <F4A33, W4A33> mm (in.) 0.60-0.85 (.024-.034)
Transfer idler gear preload <F4A22> Nm (ft.lbs.) 0.8 (1)
Center differential side gear end play <W4A33> mm (in.) 0.01-0.03 (.0004-.0012)
Front output shaft end play <W4A33> mm (in.) 0.055-0.115 (.0022-.0045)
Transfer <W4A33>
Drive bevel gear starting torque Nm (ft.lbs.) 1.7-2.5 (1.23-1.81)
Driven bevel gear starting torque Nm (ft.lbs.) 1.0-I .7 (0.72- 1.23)
Bevel gear backlash mm (in.) 0.08-0.13 (.0031-.0051)
IALVE BODY SPRING IDENTIFICATION CHART

Part name Wire diameter Outside dia. Length No. of turns
mm (in.) mm (in.) mm (in.)
Regulator valve spring 1.4 (055) 15 i.59) 52 (2.05) 11.5
l-2 shift valve spring 0.6 (024) 7.6 t.299) 26.6 (1.047) 13.5
Pressure control valve spring 0.45 (0177) 7.6 (.299) 21.3 (.839) 8.5
Rear clutch exhaust valve spring 0.7 (028) 6.8 (.268) 27.4 (1.079) 12.5
End clutch valve spring 0.6 (.024) 6.6 (260) 24.4 (.961) 15.5
2-3 shift valve spring 0.8 (.031) 7.0 (276) 27.5 (1.883) 15.5 ‘4
N-R control valve spring 0.7 (028) 9.2 (.362) 32.1 (1.264) 8.5
Reducing valve spring 1.2 (047) 8.9 (350) 29.5 (1.161) 12.5 ’ -*
Line relief spring 1.0 l.039) 7.0 (276) 17.3 (.681) 10
Torque converter valve spring 1.3 (051) 9.0 (.354) 22.6 i.890) 9.5
Shift control valve spring 0.5 (020) 5.7 (224) 26.8 (1.055) 22 ’
FFyl;;;lutch control valve spring 0.7 (.028) 6.2 (.244) 14.2 (.559) 9.5 I
SPACER SET
I Part name Thickness mm (in.) Part No. “’

Spacer set 1.4 (055). 1.0 l.040) MD997854
(for adjustment of input shaft end play) 1.4 (.055), 1.2 (047) MD997847
1.8 (.071), 1.4 l.055) MD997848: :! ’
1.8 (.071), 1.6 (.063) fQlD997849 ” .’
2.2 (.087), 1.8 (.071) MD997850
2.2 (.087), 2.0 (.079) MD997851
h
2.6 (.102), 2.2 (.087) MD997852 “-
2.6 (.102), 2.4 i.095) M D997853
AUTOMATIC TRANSAXLE - SDecifications
SPACER AND SNAP RING
Part name Thickness mm (in.) Identification mark Part We. ’
,1,
Snap ring (F4A22) 1.82.(.0717) None MD722538
(for transfer drive gear end play
adjustment) 1.88 (.0740) Blue MD721014
1.94 (.0764) Brown MD721015
2.00 (0787) None MD721016
2.06 (.081 I) Blue MD721017
2.12 (.0835) Brown MD722538
Spacer (F4A22) 1.20 (0472) 20 MD7231 60
(for adjustment of transfer shaft end play) 1.23 (0484) 23 MD7231 61
1.26 (.0496) 26 MD7231 62
1.29 (0508) 29 MD7231 63
1.32 (0520) 32 MD7231 64
1.35 (0531) 35 MD7231 65
1.38 (0543) 38 MD7231 66
1.41 (0555) 41 MD723167
1.44 (.0567) 44 MD7231 68
1.47 (.0579) 47 MD723169
1.50 (.0591) 50 MD7231 70
1.53 (0602) 53 MD7231 71
1.56 (.0614) 56 MD723172
1.59 (0626) 59 Md@75,
_ . ,_ 1.62 (.0638) 62 MD723174~:
1.65 (0650) 65 MD7231 75
1.68 (.0661) 68 MD7231 76
1.71 (.0673) 71 MD7231 77
1.74 (.0685) 74 MD7231 78
1.77 (.0697) 77 MD7231 79
1.80 (.0709) 80 MD7231 80
Snap ring (F4A22) 1.6 (.063) None MD955630

[for adjustment of front clutch and rear clutch 1 . 7 ( . 067) Brown MD730930
snap ring clearance)
1.8 (.071) Blue MP955631
1.9 l.075) None ‘MD73Q93i
2.0 f.079) Brown M~$G-$$?*
2.1 (.083) Blue M D730932
2.2 (.087) None MD955633
2.3 (.091) Brown M D730933
2.4 (.095) Blue M D955634
2.5 i.098) None MD730934
2.6 (.102) Brown MD955635
2.7 (106) Blue MD730935
2.8 (.I 10) None MD955636
2.9 (.114) Brown MD730936
3.0 (118) Blue MD955637
_-
Spacer (F4A33-W4A33) 0.62 (.0244) 62 MD737444
for adjustment of transfer driven gear 0.65 (0256) 65 MD737445
icenter differential case) preloadl
0.68 (.0268) 68 MD737446
0.71 (0280) 71 MD737447
21-162 AUTOMATIC TRANSAXLE - Specifications
*:
Part name Thickness m m ( i n . ) I d e n t i f i c a t i o n m a r k P& No. ’
Spacer (F4A33-W4A33) 0.74 (.0291) 74 M D728802
[for adjustment of transfer driven gear 0.77 (0303) 77 MD72@Y3
(center differential case) preloadl
0.80 (0315) 80 M D728804
0.83 (0327) 83 M d728805
0.86 (0339) 86 MD728806
0.89 (0350) 89 MD728807
0.92 (0362) 92 MD728808
0.95 (10374) 95 MD728809
0.98 (0386) 98 ~I~728810 ,
1 .Ol (.0398) 01 MD72& 1
1.04 (.0409) 04 MD72881 2
1.07 (.0421) 07 MD72881 3
1 .I0 (0433) IO MD72881 4
1 .I3 (.0445) 13 MD72881 5
1 .I6 (0457) 16 MD72881 6
1.19 i.0469) 19 MD72881 7
1.22 (0480) 22 MD72881 8
1.25 i.0492) 25 MD72881 9
1.28 (0504) 28 MD728820
1.31 (0516) 31 MD728821
Pressure plate 5.9 (232) A MD731 736
(for
play) adjustment of low/reverse brake end 6.0 (.236) 0 MD731 737
6.1 (240) 1 MD731 738
6.2 (.244) 2 MD731 739
6.3 (.248) 3 MD731 740
6.4 (.252) 4 MD731 588
6.5 (.256) 5 MD731 741
6.6 (.260) 6 MD731 742
6.7 (264) 7 MD731 743
6.8 (.268) 8 MD731 744
6.9 (.272) 9 MD731’745,
Spacer (F4A33sW4A33) 0.83 (0327) 83 MD720937
(for adjustment of differential case preload) 0.86 l.0339) 86 MD720938
*: W4A33 o n l y 0.89 (0350) 89 M D720939
0.92 (.0362) 92 M D720940
0.95 (.0374) 95 MD720941
0.98 (0386) 98 MD720942
1 .Ol* i.0398) 01 MD720943
1.04 (.0409) 04 MD720944
1.07 (.0421) 07 MD720945
1 IO” (.0433) J M D7 10454
1 .I3 (0445) D MD700270
1.16 (0457) K MD710455
1.19* (.0469) L MD710456
1.22 (0480) G M D7’00~71
1.25 t.0492) M rviD7~;04’57
1.28” (.0504) N MD710458
1.31 (0516) E MD706574
AUTOMATIC TRANSAXLE - SDecifications
Part name Thickness mm (in.) Identification mark Part No.

Spacer (F4A33) 1.34 (0528) 0 MD71 0459
(for adjustment of differential case preload) 1.37 (.0539) P MD7 l&O
Snap ring (F4A33eW4A33) 1.76 (.0693) Brown MD73331 4
(for adjustment of output flange bearing end 1.82 (0717) None MD722538
play)
1.88 (.0740) Blue MD721014
1.94 (.0764) Brown MD72101 5
2.00 (.0787) None MD721016
2.06 (.081 I) Blue MD721 017
2.12 (0835) Brown MD722539
2.18 (.0858) None MD73331 5
Snap ring (F4A33eW4A33) 1.3* (.051) None MD731 747
(for adjustment of front clutch and rear 1.4” (.055) Blue MD731 748
clutch end play)
1.5 LO59) Brown MD731 749
*: Rear clutch only
1.6 (063) None MD731 750
1.7 (.067) Blue MD731 751
1.8 (071) Brown MD731 752
1.9 (075) None MD731 753
2.0 i.079) Blue MD731 754
2.1 (083) Brown MD731 755
2.2 (.087) None MD731756
2.3 t.091) Blue MD73i757
2.4 l.094) Brown MD731758
Snap ring 1.05 (04) White MD71 5800
r;oreydJustment of end clutch snap ring clear- 1.30 ( 05) Yellow MD715801
1.55 (.06) None MD715802
1.80 (.07) Green Md71.5803
2.05 (.08) Pink MD71 5804
Spacer (F4A22) 1.85 (.073) H MD700272

‘for adjustment of differential case preload) 1.94 (.076) cc MD71 5956
2.03 (.080) FF MD71 5959
2.12 (.083) II MD715962
2.21 (.087) LL MD71 5965
2.30 1.091) 00 MD71 5968
2.39 l.094) RR MD71 5971
spacer 0.75-0.82 (.0295-.0323) MD722986
for adjustment of differential pinion and side 0.83-0.92 (.0327-.0362) MD722985
jear backlash)
0.93- 1 .OO (.0366- .0394) w&@
1 .01-l .08 (.0398-.0425) MD72&%3 ’
1.09-1.16 (.0429-.0457) MD722982
spacer (W4A33) 1 .I6 (.0457) 16 M D736929

for adjustment of front output bearing
Ireload) 1.19 (.0469) 19 MD736751
1.22 (.0480) 22 MD736931
1.25 l.0492) 25 MD7261 66
1.28 (.0504) 28 MD718517
1.31 (0516) 31 MD718518
1.34 LO5281 34 MD718519
21-164 AUTOMATIC TRANSAXLE - SDecifications
Part name Thickness mm (in.) Identification mark Part Np.
Spacer (W4A33) 1.37 (.0539) 37 MD77 85&I::

(for adjustment of front output bearing
preload) 1.40 (.0551) 40 MD79&21
1.43 (.0563) 43 MD718622
1.46 (.0575) 46 .&&g~ :
1.49 (.0587) 49 tiD718ji4’~“ ,.

1.52 (.0598) 52 MD718525
1.55 (.0610) 55 MD718526
1.58 (0622) 58 MD71 8527
1.61 (0634) 61 MD71 8528
1.64 (.0646) 64 MD71 8529
1.67 (0657) 67 MD718530
1.70 (.0669) 70 MD71.8531
1.73 (.0681) 73 ‘MD721’959
1.76 (.0693) 76 MD721960
Spacer (W4A33) 0.53-0.60 (.0209-.0236) 28 MD727928
[for adjustment of center differential front 0.72-0.76 (.0284-.0299) 3 0 MD727930
side gear end play)
0.85-0.92 (.0335-.0362) 32 MD727932
1 .01-l .08 (.0398-.0425) 34 MD727934
1.17-l .24 (.0461-.0489) 41 MD727941
Spacer (W4A33) 0.59-0.66 (.0232-.0260) 73 MD724973

Ifor adjustment of center differential rear 0.75-0.82 (.0295-.0323) 4 6 MD724946
side gear end play)
0.93-I .OO (.0366-.0394) 8 1 MD724981
1.09-I .I6 (.0429-.0457) 4 3 MD724943
1.25-1.32 (.0492-.0520) 72 MD724972 __
Spacer (W4A33) 1.34 (.0528) 34 MD723606
Ifor adjustment of drive bevel gear mount) 1.37 i.0539) 37 MD723601
1.40 (0551) 40 MD723602
1.43 (.0563) 43 MD723603
1.46 (.0575) 46 MD723604
1.49 (.0587) 49 MD723605
1.52 (.0598) 52 M D723606
1.55 (0610) 55 M D723607
1.58 (.0622) 58 M D723608
‘I .61 (.0634) 61 MD723609
1.64 (0646) 64 MD7261 70
1.67 (.0657) 67 MD726471 .‘i
,.,
jpacer (W4A33) 1.28 (0504) B28 MD726167
for adjustment of drive bevel gear train
Ireload) 1.31 (0516) B31 MD7261 68
1.34 (.0528) B34 MD7261 69
1.37 (.0539) B37 M D724326
1.40 (0551) B40 MO724E27
1.43 (.0563) B43 MD724328’
1.46 (0575) B46 MD724329
1.49 (.0587) B49 M D724330
1.52 (.0598) B52 M D724331
1.55 (.0610) B55 MD724332
1.58 (0622) B58 M D724333
1.61 (0634) B61 MO724334
AUTOMATIC TRANSAXLE - Specifi6atioris
Part name Thickness mm (in.) Identification mark ‘Part ‘);ilb. I”

Spacer (W4A33) 1.64 (.0646) B64 MD724335
(for adjustment of drive bevel gear train 1.67 (.0657) B67 MD724336
preload)
1.70 (.0669) B70 MD724337
1.73 (0681) B73 M~724338
1.76 l.0693) B76 MD724339
1.79 (.0705) B79 MD724340
1.82 (0717) 882 MD724341
1.85 (.0728) B85 MD724342
Spacer (W4A33) 1.19 (.0469) 19 MD7261 72
(for adjustment of driven bevel gear train
preload) 1.22 (0480) 22 MD722081
1.25 (.0492) 25 MD722082
1.28 (0504) 28 MD722683
1.31 (0516) 31 MD722084
1.34 (0528) 34 MD722085
1.37 (.0539) 37 MD722086
1.40 (0551) 40 MD722087
1.43 (.0563) 43 MD722088
1.46 (0575) 46 MD722089
1.49 (.0587) 49 MD7228090
1.52 (0598) 52 .MD722091
1.55 (0610) 55 MD722092
1.58 (0622) 58 MD722093
Spacer (W4A33) 1.61 (0634) 61 MD722694
~for adjustment of driven bevel gear train
xeload) 1.64 (0646) 64 MD722095
1.67 (.0657) 67 MD722096
1.70 (.0669) 70 MD722097
1.73 (0681) 73 MD722098
1.76 (.0693) 76 MD722099
1.79 (.0705) 79 MD7221 00
1.82 (0717) 82 MD7221 01’
1.85 (0728) 85 MD7221 02
1.88 (.0740) 88 MD7221 03
1.91 (.0752) 91 MD7221 04
1.94 (.0764) 94 MD7221 05
spacer (W4A33) 0.13 (0051) 13 MD720353
for adjustment of driven bevel gear mount) 0.16 (.0063) 16 MD720354
0.19 (0075) j19 MD720355
0.22 (0087) 22 M~$,gjg~~
0.25 (.0098) 25 ,:!, MD’ly&““$
ti&2&58
0.28 (.Ol
0.31 10)
(0122) 328””
1 “’
e> I hbf,&$&
0.34 (0134) 34 ,‘I Mbf2tiyo
0.37 (0146) 37 MD720361

0.40 (.0517) 40 MD720362
0.43 (.0169) 43 MD726363
0.46 (0181) 46 MD720364
0.49 (.0193) 49 MD720365
0.52 (0205) 52 MD720366
21-166 AUTOMATIC TRANSAXLE - SDecifications
,. _ , ,_ .
TORQUE SPECIFICATIONS Nglcc-
-.
Items Nm ft*lgk+ ‘. St. :“.. (1.
Tie rod end to knuckle 24-35 17-25 I ~. ‘,

Lower arm ball joint to knuckle 60-72 43-52
Transaxle mounting bracket to transaxle 60-80 43-58
Special bolts 46-53 33-38
Selector lever assembly mounting bolts 9-14 7-10
Shift lock cable to selector lever assembly 4-6 3-4
Clamp to body 4-6 3-4
Starter motor mounting bolt 27-34 20-25 i::
Oil cooler mounting bolt 8-12 6-8
Eye bolt 30-35 22-25
Tube bracket 3-5 2-4
Tube bracket 8-12 6-8
Oil cooler hose clamp 4-6 3-4
Hose bracket 3-5 2-4
Cover to selector knob 2.0 or more 1..4 or more
Selector knob to lever assembly 2.0 or more 1.4 or more
Bell housing cover to engine 10-12 7-9
Transaxle mounting bolt [lo mm l.40 in.) diameter bolt] 10-12 7.2-8.7
Transaxle mounting bolt [8 mm I.31 in.) diameter bolt] 30-35 22-25
Torque converter to drive plate 73-77 53-55
Transaxle control cable to body 9-14 7-10
Transaxle control cable adjusting nut IO-14 7-10
Drive shaft nut 200-260 144-188
Transfer mounting bolt 60-80 43-58
ndicator panel 1 .o-2.0 0.7-14
-ever assembly to bracket assembly 14-20 10-14
3ight member installation bolt
Front 80- 100 58-72
Rear 70-80 51-58
;usset 70-80 51-58
Zenter bearing bracket 36-46 26-33
:l=4A22>
Oil pan bolt 10-12 7-9
Drive plate-to-converter tightening bolt 46-53 34-38
Pressure check plug 8-10 6-7
Pulse generator mounting bolt IO-12 7-9
Bearing retainer screw 17-22 12-15
Lock plate bolt 35-45 26-32
Converter housing bolt 19-23 14-16
One-way clutch outer race bolt 25-35 18-25
D i f f e r e n t i a l d r igear
ve bolt 130-140 94-101
Manual control lever nut 17-21 13-15
Manual control shaft set screw 8-10 6-7
AUTOMATIC TRANSAXLE - Seecificdions
,I
Items Nm ‘ft.lbs.
Inhibitor switch IO-12 7-9
Sprag rod support bolt 20-27 15-19 ,,
Pump housing-to-reaction shaft support bolt 10-12 7-9
O i l pump
assembly mounting bolt 15-22 11-15
Valve body bolt 4-6 3-4
Valve body assembly mounting bolt 10-12 7-9
Oil filter bolt 5-7 4-5
Speedometer sleeve locking plate bolt 3-5 2-4
End clutch cover 6-8 5-6
Kickdown lock nut 25-32 18-23
< F4A33. W4A33 >
Air exhaust plug 30-35 22-25
Center bearing retainer stopper bolt <W4A33> 4-6 3-4
Center differential drive gear bolt <W4A33> 70-80 51-57
Differential cover bolt 10-12 7-9
D i f f e r e n t i a l d r igear
ve bolt 130-140 94-101
Differential front bearing cap bolt 60-80 43-58
Differential rear bearing retainer bolt 30-40 22-29
End clutch cover bolt 10-12 7-9
Front bearing retainer bolt <W4A33> 43-55 32-39
Idler gear cover bolt 10-12 7-9
Idler shaft lock bolt 31-44 22-32
Inhibitor switch bolt IO-12 7-9
Kickdown servo lock nut 25-32 18-23
Manual control lever nut 17-21 12-15
Manual control shaft set screw 8-10 6-7 -_
Oil drain bolt 30-35 22-25
Oil filter bolt 5-7 4-5
Oil level
gaugeguide bolt 20-27 15-19
Oil pan bolt 10-12 7-9
Oil pressure
check plug 4-6 3-4
O i l pump
assembly mounting bolt 19-23 13-17
Oil pump bolt 10-12 7-9
Output bearing retainer bolt 20-27 15-19
Output flange bearing retainer bolt 17-22 12-16 "/
Parking rod support bolt 20-27 15-19
Pulse generator bolt IO-12 7-9
Roll stopper bracket bolt 43-55 32-39 '
Shift control cable bracket bolt 20-27 15-19
Speedometer gear locking plate bolt 4-6 3-4
Transaxle mount bracket bolt 60-80 $-,58
Valve body assembly mounting bolt 10-12 7-9
Valve body bolt 4-6 3-4
-.
21-168 AUTOMATIC TRANSAXLE - Specifications
-
TRANSFER <W4A33>
Items Nm ft.lbs.
Cover mounting bolt 4-6 ‘3-4 .
Driven bevel gear lock nut 140-160 162-115 ‘i
Extension housing mounting bolt 15-22 11-15 ‘
Oil drain plug 30-35 22-25
Oil filler plug 30-35 22-25
Transfer case adapter mounting bolt 35-42 26-30
Transfer cover mounting bolt 35-42 36-30
LUBRICANTS W1CD-C
Items Specified lubricant Quantity
Transaxle fluid liters (qts.) MOPAR ATF PLUS (Automatic transmission 6.1 (6.4) <F4A22>
fluid type 7176) or Dia ATF SP 7.6 (8.0) <F4A33. W4A33>
or equivalent :‘,
Key interlock cable MOPAR Multi-mileage Lubricant Part As required

Select lever assembly No. 2525035 or equivalent
Bushing, sleeve, spring,
pushbutton and lock cam
Drive shaft oil seal lip MOPAR ATF PLUS (Automatic transmission As required
fluid type 7176) or Dia ATF SP
or equivalent
SEALANTS AND ADHESIVES N2lcE-c

<F4A22>
Transaxle case gasket Silicone grease
Bearing retainer screw bolts MOPAR Part No.4318031 or MOPAR Part

<W4A33>
Transfer extension housing-Transfer adapter MITSUBISHI Genuine Part No.997740 or

equivalent : :t;p,
Front bearing retainer bolts MOPAR Part No.4318031. or MOPAR ‘Part”’ ‘~’ “,“i
No.4318032 or equivalent ’ ‘. :“’
Center differential flange bolts
Air breather MOPAR Part No.4318025 or equivalent

AUTOMATIC TRANSAXLE - Special Tools
SPECIAL TOOLS N2lDA-C
easuremen
torque (W4A33)
21-170 AUTOMATIC TRANSAXLE - Special Tools
Installation of bearing
‘.
Removal of oil pump
MD998337 Spring compressor Use the MD998907 and MD998338

AUTOMATIC TRANSAXLE - SDecial Tools 21~171
MD998341 Kickdown servo tool Removal and installation of kickdown servo
Wrench adapter “6” Removal and installation of transfer idler shaft
Installation of transfer shaft rear bearing and
M D998367 Snap ring installer Assembly of the end clutch
eanng remover
Installation of drive shaft oil seal (W4A33)
Wrench adapter Measurement of transfer driven bevel gear

drive torque (W4A33)
Installer-200 Driving of beanng
Installer adapter (52)

AUTOMATIC TRANSAXLE - Special Tools

MD998830 Installer adapter (66) Driving of bearing
MD998904 Bolt Pull-out of idler shaft
M D998905 Handle Removal and installation of center support
MD998906 Wrench adapter Preload measurement of transfer idler shaft

Measurement on transfer idler gear
MD998907 Spring compressor Disassembly of front clutch
MD998908 Bearing installer Installation of transfer shaft front bearing
M D998909 Bearing installer Installation of transfer shaft bearing
MD99891 0 Bearing installer Installation of transfer shaft rear bearing
MD99891 1 Bearing installer Installation of transfer driven gear bearing

Number Name I Use
MD99891 5 Wrench adapter Use the MD99891 8
MD99891 9 Snap ring installer Reassembly of end clutch

AUTOMATIC TRANSAXLE - Troubleshooting
Based upon use of the troubleshooting TROUBLESHOOTING ” N21EeAY

guide, the probable location of the prob-
lem should be estimated. Functional malfunctions of the ELC4A/T can lead to other
problems, such as those described below:
(1) Improper maintenance and/or adjustments
(2) Malfunctions of the electronic control functions
Checks should be made of fluid levels (3) Malfunctions of mechanical functions
and the condition of the ATF, as well as
(4) Malfunctions of hydraulic control functions
bles; adjustments should then be made if (5) Malfunctions of engine performance
etc.
In order to properly determine (“Troubleshoot”) the source of
these malfunctions, it is first essential to methodically ques-
tion the user concerning the details of the problem, such qs
If a presumption has been made that the condition of the problem, the situation at the time the
there is an abnormal condition some-
problem occurred, and any other relevant information, all in as
check the fault code, in order to determine much detail as possible. The user shoutd also be asked
the probable location of the problem, by whether or not the problem has occurred more than once,
and under what conditions.
Subsequently, certain tests should be conducted in a certain
order, as described at the left.
When the abnormal system is discovered,

check each element (sensors, etc.) one by
one, and make repairs as necessary.
When the abnormal condition is pre-

sumed to be in the orI-pressure-control
system, check by making an oil-pressure
“~^ II_
If the problem is unusually dirty ATF,

of the clutch or brakes, or an abnormal
condition of the transaxle itself, disassem-
21-176 AUTOMATIC TRANSAXLE - Troubleshooting
TROUBLESHOOTING GUIDE
Presumed cause
items of high priority during inspection.

= Throttle position sensor SCSV = Shift control solenoid valve
- Transaxle malfunction of shift-s lise, other
g
-09
92
pl
a8
g.E!
Pp
.G c
55
.-,
fi$
8
0%
-
T -
1 -
3 -
4 -
5 -
6
- -
7 -
s -
s -
ro X
- -
ii -
i?
- -
13 X X
-
14 X -
ii- -
16 -
n -
Is
- -
19
- -
!O
- -
!l
-
!2
- s--
-
!3
- -
!4 X
- -
!5
- -
!6
-
c -
!6
- - -
!9 -
,o x
- -
n - -
i- - -
i? - -
r - -
ii- - -
k- - -
i i X
-
-
ir X X
- -
PSCV = Pressure control solenoid valve
DCCSV = Damper clutch control solenoid valve
i
DIAGNOSIS AND TEST
FLUID LEVEL AND CONDITION
1. Drive until the fluid temperature reaches the usual tem-
perature [70-80°C (160- 18O”F)I.
torque converter and hydraulic circuit with fluid, then place
lever in “N” Neutral position. This operation is necessary to
be sure that fluid level check is accurate.
dipstick. Then take out the dipstick and check the condition
of the fluid.
conditions.
l If there is a noticeably great amount of metal particles in
the fluid.
5. Check to see if fluid level is in “HOT” range on dipstick. If
fluid level is low, add automatic transaxle fluid until level
reaches “HOT” range.
Low fluid level can cause a variety of conditions because it
09P0010
allows pump to take in air along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressures will be erratic.
cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of automatic transaxle
fluid.
Fluid level must be In either case, air bubbles can cause overheating, fluid
within this range. oxidation, which can interfere with normal valve, clutch,
escaping from transaxle vent where it may be mistaken for
09PoOll
a leak.
CONTROL CABLE
Whether control cable is properly adjusted can be confirmed by
checking whether inhibitor switch is performing well.
1. Apply parking brakes and service brakes securely.
2. Place selector lever to “R” range.
3. Set ignition key to “ST” position.
4. Slowly move the selector lever upward until it clicks as it
0” fits in notch of “P” range. If starter motor operates when
lever makes a click, “P” position is correct.
Two302
5. Then slowly move selector lever to “N” range by the same
procedure as in foregoing paragraph. If starter motor
operates when selector lever fits in “N”, “N” position is
correct.
6. Also check to be sure the vehicle doesn’t begin to move
and the lever doesn’t stop between P-R-N-D.
7. The control cable is properly adjusted if, as described
above, the starter motor starts at both the “P” range and
the “N” range.
AUTOMATIC TRANSAXLE - Troubleshooting 21-179
OBTAINING FAULT CODES
(1) Connect the voltmeter to the connector for diagnosis.
(2) Read the output fault codes.
Then follow the remedy procedures according to the
“FAULT CODE DESCRIPTION” on the following page.
NOTE
l As many as a maximum of terr fault codes, in the
sequence of occurrence, can be stored in the Random
Access Memory (RAM) incorporated within the control
unit.
l If the number of stored fault codes or fault patterns
exceeds ten, already stored fault codes will be erased,
in sequence beginning with the oldest.
l Do not disconnect the battery until all fault codes or
fault patterns have been read out, because all stored
fault codes or fault patterns will be canceled when the
battery is disconnected.
(3) If the fail-safe system is activated and the transaxle is
16R1336 locked in 3rd gear, the fault code in the Fail-Safe Code
@: ELC-4PJT Description will be stored in the RAM.
@I: Diagnosis control Three of these fault codes can be stored.
0: Ground (4) The cancelation will occur if, with the transaxle locked in
3rd gear, the ignition key is turned to the OFF position, but
the fault code is stored in the RAM.
21480 AUTOMATIC TRANSAXLE - Troubleshootina
FAULT CODE DESCRIPTION
Code Output pattern
No. Description Remedy
11 Abnormal increase of TPS output l Check the throttle position sensor

connector.
n l Check the throttle position sensor
itself.
l Adjust the throttle position sensor.
12 Abnormal decrease of TPS output l Check the accelerator switch
(Code No. 24output or not).
Malfunction of the throttle-

position sensor or incorrect
adjustment
Damaged or disconnected wiring l Check the oil temperature sensor

of low oil temperature sensor connector.
l Check the oil temperature sensor
itself.
16 Short circuit of high oil tempera-

ture sensor
Damaged or disconnected wiring

of high oil temperature sensor or
short-circuit of low oil tempera-
ture sensor
21 Damaged or disconnected wiring l Check the kickdown servo switch

n of the kickdown servo switch
l
connector.
Check the kickdown servo switch
itself.
22 Short circuit of the kickdown ser-

nn vo switch
23 Damaged or disconnected wiring l Check the ignition pulse signal line.

of the ignition pulse pick-up cable
24 Short circuit of the accelerator l Check the accelerator switch con-

switch or improper adjustment nectar.
l Check the accelerator switch itself.
l Adjust the accelerator switch.
31 Damaged or disconnected wiring l Check the pulse generator A and

u’u I n of the pulse generator A
l
pulse generator B themselves.
Check the vehicle speed reed
switch (for chattering).
32 Damaged or disconnected wiring

of the pulse generator B
uuLnJ-l-
12A0104
12A0107
AUTOMATIC TRANSAXLE - Troubleshootina
Code Output pattern .> ‘)

Description Remedy
No.
41 Damaged or disconnected wiring l Check the solenoid valve connec-

of the shift control solenoid valve tor.
nnnn A l Check shift control solenoid valve C
itself.
42 Short circuit of the shift control
uuu-mn solenoid valve A

of the shift control solenoid valve tor.
- B l Check shift control solenoid valve E
itself.
44 Short circuit of the shift control

uuvuwln solenoid valve B
45 Damaged or disconnected wiring l Check the, solenoid valve connec-
uuuumn of the pressure control solenoid tor. ,.

valve l Check the pressure control sole-
noid valve itself.
46 Short circu.it of the pressure con-

J-~-,,-= trol solenoid valve

of the damper clutch control sole- tor.
nnnn~ noid v a l v e l Check the damper clutch control
solenoid valve itself.
48 Short circuit of the damper clutch

nnnn control solenoid valve
Malfunction of the damper clutch l Check the damper clutch hydraulic

system pressure system.
l Check the damper clutch control
solenoid valve itself.
l Replace the control unit.
51 First gear non-synchronous l Check the pulse generator A and
UUUUI~
pulse generator-B connectors.
l Check pulse generator A and pulse
generator B themselves.
l Rear clutch slippage.
52 Second gear non-synchronous l Check the pulse generator A and

pulse generator B connectors.
uuuul nn l
l
Check pulse generator A and pulse
Rear clutch slippage.
l Kickdown brake slippage.
I-Y I”*
12Ao106
Code
Output pattern Description Remedy
No.
53 Third gear non-synchronous l Check the pulse generator A output

circuit harness.
l Check the pulse generator A and
UUUULnnn- l Check the pulse generator A and
pulse generator B themselves.
l Front clutch slippage.
l Rear clutch slippage.
54 Fourth gear non-synchronous l Check the pulse generator A output
circuit harness.
l Check the pulse generator A and
uuuuLnMn- l Check pulse generator A and pulse
l End clutch slippage.
l Kickdown brake slippage.
12A0106
FAIL-SAFE CODE DESCRIPTION

Code Fail-safe Note (relation
Output pattern Description to fault code)
No.
81 Damaged or disconnected 3rd gear (D) or 2nd 31

wiring of the pulse generator gear (2, L) hold
A
82 Damaged or disconnected 3rd gear(D) or 2nd 32

wiring of the pulse generator gear (2, L) hold
B
83 Damaged or disconnected 3rd gear hold 41,42

wiring, or short circuit, of shift
control solenoid valve A
84 Damaged or disconnected 3rd gear hold 43,44

wiring, or short circuit, of shift
control solenoid valve B
85 Damaged or disconnected 3rd gear(D) or 2nd 45,46

wiring, or short circuit, of the gear (2, L) hold
pressure control solenoid
valve
86 Shift steps non-synchronous 3rd gear (D) or 2nd 51,52,53,54

gear (2, L) hold
12LO296
AUTOMATIC TRANSAXLE - Troubleshooting 214%3
TRANSAXLE CONTROL UNIT
-‘” . The 42 pin connector is for increased sensor input. Terminal
layout for the 42 pin connector is as shown below.
TFA0360
101. Damper clutch control solenoid valve <F4A22> 51. Inhibitor switch (PI
102. Shift control solenoid valve A 52. Inhibitor switch (8)
103. Oil temperature warning light <W4A33> 53. Inhibitor switch (N)
104. Power supply 54. Inhibitor switch (D)
105. Ground 55. Inhibitor switch (2)
106. Pressure control solenoid valve 56. inhibitor switch (L)
107. Shift control solenoid valve B 57. Overdrive switch
108. - 58. Pulse generator B
109. Power supply 59. Pulse generator B
110. Ground 60. Pulse generator A
61. Pulse generator A
1. Ground 62. Ground
L. - 63. Ignition pulse
3. Accelerator switch 64. Power mode signal
4. -
5. Diagnosis output terminal
6. Air conditioner relay signal
7. -
8. Diagnosis control terminal
9. -
IO. Power supply (Backup)
11. Kickdown servo switch
12. -
13. -
14. Oil temperature sensor
15. High oil temperature sensor <F4A33.W4A33>
17. Sensor ground
18. Vehicle speed reed switch
21-184 AUTOMATIC TRANSAXLE - Troubleshootina
ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER
Selector
lever
position
P
Cl Front clutch
C2 Rear clutch
Bl Kickdown brake
82 Low-reverse brake
SHIFT PAlTERNS
C3 End clutch OWC Oneway clutch Two shift patterns are pre-stored in the control unit of this
transaxle. One is the power pattern (for more powerful
performance), and the other is the economy pattern (for
improved fuel consumption and quieter operation).
The driver can select and switch to the desired pattern by using
the power/economy select switch on the center console.
The solid lines shown in these shift patterns indicate up-shifts,
and the broken lines indicate down-shifts. The reason why
there is a difference between the shift points for up-shifts and
for down-shifts is so that up-shifts and down-shifts will not
occur frequently when driving at a speed in the vicinity of the
shift point.
When the vehicle is stopped, there is a shift to 2nd gear in
order to obtain a suitable “creeping”, but when the accelerator
pedal is then depressed the vehicle starts off in 1st gear.
AUTOMATIC TRANSAXLE - Troubleshooting 21483
1.8L Engine (F4A22-2-MPD)
:,
+. P r a n g e
100 I
I
80 c I
I/
z /I/i A’ /
b
- 60 e I I
F
'!z Jk///@ /' I
: 40 I
a, I
z I
2 I
e 20- I
I /' IA (L) 24.3 (2,L) 3-14
(Ds)
I I I I I
Idle 1,000 2,000 3,000 4,000 5,000 6,000
Transfer shaft speed r/min. 1 ,
1 I
(ii) ;$ (::I (7:) (4:) (::) (i;) (ii) (ii) (56) 90 (62) 100 (68) 110 (75) 120 (81) 130 (87) 140 (93) 150 (99) 160 (106) 170
Vehicle speed km/h (mph)
TFA0486
E range
I
- 60 I
P I
!
40.
a, I
t:
!
ILIlt?
1,000 2,000 3,000 4,000 5,000~ 6,000
Transfer shaft speed r/min.
1 , 1 I.
$1 ('69 (::, (% (%, $7) (i?) (ii, & (56) 90 (62) 100 (68) 110 (75) 120 (81) 130 (87) 140 (93) 150 (99) 160 (106) 170
TFA0487
2.0L DOHC Engine (F4A22-2-MPDI)
P range
100 I I
I
i
801 -
/ I/
i
-z
2- I
;
60
.P-
&
8 40
a,
s
2
e 20
I
2"c3 (2.L) 39+4 (DA
Idle
1,000 2,000 3,000 4,000 5,000 6,000
I
ii k? 6 6) & (35:) (t;, (ii, (49) 80 (56) 90 (62) 100 (68) 110 (75) 120 (81) 130 (87) 140 (93) 150 (99) 160 (106) 170 (111) 180 (118) 190
TFA0488
E range
100 I I
I I I
1 I -- I i
80 I I II/ YI/ // II I I! I
1 4 2 (D-2) 214 3 (D) 4 (DA I J 1
/ / I
I /A’ I
o-- m I I I
“1
c --
s I
O" 40 !
al
5 I
F2 24 3 (2,L) 3-14 P3)
20 I
I 1 I
ldlel I
1,000 2,000 3,000 4,000 5,000 6,000
I 1 I
ii, ('$ (:;, (%) (;:) & (:?, (& (::I (56) 90 (62) 100 (68) 110 (75) 120 (81) 130 (87) 140 (93) 150 (99) 160 (106) 170
TFA0489
2.0L DOHC Turbo Engine (F4A33-W4A33)
P range
100 I
I I II
1 .*-2 (6.2,
I
80
I
27’3 (2.L) 3-I
I
$3,
3,000 4,000 5,000 6,000

I I I I I II I I I 1 1 I I
90 100 110 120 130 140 150 160
coo, ;fi (:;j (::j (i:, (?, (!;I (ii, (% (56) (62) (68) (75) (81) (87) (93) (99,

TFA0572
E range
100 1I I I 1
I l-r
II
II I I I-I
I-
80 / I L / II
c 3 --4 !D,)
40 I 1
: I
a I
I I
E
,o I
I I
f 20 I
I
2 +- 3 (2.L) 3--
I , (4D3,
I
Idk1 I .vvv 1 nnn
L,““” '1 nnn
L),““” A nnn
7,““” !i nnn
-,--- 6.01
~, DO

I I I I I I I I I I I I I I I I I
100 110 120 130 140 150 160
(E, (69 (:;, (% (4:) (% (% (ii, (ii, (% (62) (68) (75) (81) (87) (93, (99,
TFA0575
INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS
1
Improper connection of
Based on the wiring diagram, connector, damaged or
check whether the continuity and + disconnected harness,
grounding of each harness is OK. or incorrect wiring con-
nection.
+
L
J
.
c Continuitv
/
J 1
4 . Reconnect the connec-

tor; repair or replace the
Normal I harness.
I \
Vary the thermo-sensitive part
uarriageu ur ursconnecrea
wiring
I
Replace the oil-

/ Chanaes of the resistance con-
tinuo& and smooth.
\ I1 temoerature sensor
I
4
, I 1750446 - N o r m a l
1: (+) side
2: (-) side
2.0L DOHC Turbo Engine
3. Throttle- Check the resistance between Damaged or discon-

osition sensor terminals 1 and 4 (1 and 2 for netted wiring
PTPS) SOHC models) of theTPS.
I I
+
TPS termrnal 3.5-6.5 S2/2O”C (68°F)
( 1
2.0L Engine
Check the resistance between
terminals 4 and 2 (2 and 3 for
SOHC models) with the engine Improper adjustment
idling after throttle-valve opening
warm-up. J
1. power 7FUO535
2. output ’ Readjust the TPS in-
3. - 4
stallation.
4. ground Resistance: approx. 0.4 kilohml
20°C (68°F)
1.8L Engine I
1. power Check for changes of the resist-

2. ground ance between terminals 4 and 2
3. output (for SOHC between terminals 3
and 2 when the throttle valve is
operated from the idling position
to the fully open position.
4
Changes of the resistance con-
tinuous and smooth.
4
Normal
Short-circuit; or dam-
_ 4, ppBgenerator Check the resistance between aged or disconnected
terminals 1 and 2 or 3 and 4. wiring :
I
Pulse generator terminals
.
(
.
4
215-275 Q/2O”C (68°F)
/
1
Replace the pulse
generator.
Normal I
1750338
I I \
5. Pulse enerator Connect the pulse generator and

body harness, and connect an
A or B ? checking w oscilloscooe.
#, -mm v3nlwdP
+ mm narillr Check with the
chassis on a dynamo or with the
\
I scope) I \
front wheels raised.
. . .,’
With the selector lever at the “L” Incorrect installation of

position and the engine running at the pulse generator, or
1,000 rpm, check the voltage malfunction,of the pulse
waveform between terminals 1 g e n e r a t o r .
and 2. I
Oscilloscope waveform I
1,8L, 2.0L DOHC 4
Non-Turbo Engine 1,000 mVp-p or higher
Noise >
/
AA
_-- 5E Improper grounding of
the pulse generator cir-
iw cuit’s shielded wiring.
171091
2.0L DOHC Turbo Engine i
,Noise
Replace the pulse
generator.
+
+ , I
500 mVp-p or higher Correct the installation

( J condition, or replace the /
pulse generator.
Noise
Normal 1
21490 AUTOMATIC TRANSAXLE - Troubleshooting
6. Pressure- Check the resistance between

terminal 1 of the solenoid valve aged or disconnected
n-1:
Short-circuit, or’@, ,,
connector and the transaxle case. wiring

1
” ,“,
Connect 12V between the trans- Foreign material caught
axle case and terminal 2; between the valve and
switch ON and OFF and check for
Solenoid valve operation noise. guide
connector terminals 1 .
1: PCSV
2: DCCSV
3: SCSV-A
4: scsv-B
I Replace the PCSV.
I
Check the resistance between Short-circuit, or dam-

7. Shift-control terminal 3 or 4 of the solenoid
solenoid valve + aged or disconnected
valve connector and the transaxle w i r i n g
(SCSV) A or B t case. t
4
4
c- 22.3 f l.5Q/20°C (68°F) J Replace the SCSV..
Connect 12V between the trans-

axle case and terminal 3 or 4;
switch ON and OFF and check for ~~~~~
operation noise of the solenoid
valve, and check the valve stroke.
4
Noise exists.
I
Normal I
a
/
Set the selector lever to “P” or

“N”, and start the engine.
I With the engine idling, de-

Dress the foot brake firmlv. I
Improper adjustment
of idling I
( Let the engine continue idling. )
Normal
G’
9. Damper clutch Check the resistance between Short-circuit 0,s” dam-
control solenoid terminal 2 of the solenoid valve too low or too aged or d&connected
valve (DCCSV) connector and the transmission wiring .: ’
1,8L, 2.0L DOHC case.
I
Non-Turbo
Engine 1 Replace the DCCSV. 1
( Standard value: 3 Q/20% )
I
Solenoid valve
connector terminals
1: PCSV
2: DCCSV
3: SCSV-A *Sticking is
4: SCSV-B usually at the
1750338 release side.
I Normal I
b adjust if necessary.
Replace the accelerator

switch.
171096
( No continuity (resistance: Q)) )

4
Normal
tinuity between terminals 3 and 4

< ‘.
Continuity exists
In the “R” range, check for con-

tinuity between terminals 4 and 7,
and terminals 10 and 11.
+
Continuity exists 7
Continuity exists
In the “D” range, check for con-

tinuity between terminals 4 and 6.
p$g
1 the inhibitor
?’ .
Continuity exists
1
In the “2” range, check for con-
Continuitv exists
In the “L” range, check for con-

4
Continuity exists
4
Normal
i
Check for continuity between the

kickdown servo switch terminal
Continuity exists
+
TFA0389 Start the engine, set to the “L”
range, and let the engine idle; “‘
check for continuity between the
kickdown servo switch terminal Poor contact (sticking)
and the transaxle case.
NOTE: Be sure the brakes are
applied during this check. 4
+ Replace the K/D servo

No continuity switch.
.
+
Normal
Disconnect the harness (both A

and B connectors) from the vehi-
Malfunction of the ori-
ginal TCU
Consider the original TCU to be
Same problem (as before TCU

exchange) occurs.
AUTOMATIC TRANSAXLE - Troubleshooting 21'495
OIL PRESSURE TESTS
.”
1. Completely warm up the transaxle.
2. Raise the vehicle by using a jack so that the drive wheels
can be rotated.
3. Connect an engine tachometer and place it in a position
where it’s easy to see.
4. Attach the special oil-pressure gauge (C-3292 or C-3293)
and the adaptor (MD998332) to each oil-pressure outlet
port.
When the reverse pressure is to be tested, the 3,000 kPa
(400 psi) type of gauge should be used.
5. Measure the oil pressure under various conditions , and

check to be sure that the measured results are within the
standard value range shown in the “Standard oil pressure
table” below.
If the oil pressure is not within the specified range, check
and repair as described in the section “Remedial steps if oil
pressure is not normal” on the next page.
m // @ Kickdown brake
Standard Oil Pressure Table
F4A22
Conditions Standard oil pressure kPa (psi)
1 N Idling Neutral 360-490

(51-70)
D 2nd gear 360-490

2 Idling (51-70)
Approx. 360-490 830-900 830-900

3 4th gear
&ON, 2,500 (51-70) (118-128) - (118-128) -
A2pp5boox. 360-490 830-900 830-900 830-900 350-450

4 3rd gear (118-128) (118-128) (118-128) - (50-643
(SWF)oFF, , (51-70)
Approx. 360-490 830-900 -

5 2 2nd gear (118-128)
2,500 (51-70)
6 L Ap”60”. 1st gear 360-490

(51-70)
- I -
l-4
1,640-2.240
(233-319)
-
1,500 (213)
or more 1 or more I
No.
T
Select
lever
Engine
speed
Shift
0 0
Reducing
pressure
KickM;vn
0
Kickdown
brake
Standard oil pressure kPa (psi)
@I
Front
clutch
0
Rear
clutch
c3
End
clutch
0
Low-
reverse
c3
Torque-
converter
position pressure pressure pressure brake pressure
position m pressure pressure
(APPM (Release) pressure
N Idling
-l---l
Neutral
L
!r$I$$
I
- - h
D Idling 2nd gear I360-480

(51-68) I
100-210
(14-30)
730-830
(104-118)
- - *
- 830-900
(SWFON, (118-128)
830-900 830-900 830-900 830-900

4 SW%FF: (118-128) (118-128) (118-128) (118-128)
Approx. 830-900 - 450-650

2 (118-128) (64-92)
2,500
Approx. 830-900 - *
6 1,000 (118-128)
Approx. ,640-2.24C II ,640-2.24C I ,640-2.24C I

2,500 (233-319) (233-319) (233-319) 450-650
7 - (64-92)
1.500 (213) 11,500 (213) 1,500 (213)
or more or more or more
NOTE
must be 10 kPa (1.4 psi) or less.
SW-ON: Switch ON the overdrive control switch
SW-OFF: Switch OFF the overdrive control switch
I+: Hydraulic pressure is generated, but not the standard value.
Remedial Steps If Oil Pressure Is Not Normal
F4A22
.,, ‘
frouble symptom Probable cause Remedy 1;
I. *Line pressures a. Clogging of oil filter a. Visually inspect the oil filter; replace the oil filte
are all low (or high). if it is clogged.
NOTE b. Improper adjustment of oil press- b. Measure line pressure @ (kickdown brake
*“Line pressures” ure (line pressure) of regulator pressure); if the pressure is not the standard
refers to oil ress- valve value, readjust the line pressure, or, if neces-
ures@,@, 48and sary, replace the valve body assembly.
@in the “Standard c. Sticking of regulator valve c. Check the operation of the regulator valve;
oil pressure table” repair if necessary, or replace the valve body
on the previous assembly.
d. Looseness of valve body tighten- d. Tighten the valve body tightening bolt and
page. ing part installation bolt. ‘- ,
e. Improper oil pump dischange e. Check the side clearance of the oil pump gehr;
pressure replace the oil pump assembly if necessary.
I. Improper reducing a. Improper line pressure a. Check the @ kickdown brake pressure (line
pressure pressure); if the line pressure is not the
standard value, check as described in item 1
above.
b. Clogging of the filter (L-shaped b. Disassemble the valve body assembly and
type) of the reducing-pressure cir- check the filter; replace the filter if it is clogged.
cuit
c. Improper adjustment of the re- c. Measure the @I reducing pressure; if it is not
ducing pressure the standard value, readjust, or replace the
valve body assembly.
d. Sticking of the reducing valve d. Check the operation of the reducing valve; if
necessary, repair it, or replace the valve body
assembly.
e. Looseness of valve body tighten- e. Tighten the valve body tightening bolt and
ing part installation bolt.
#. Improper kick- a. Malfunction of the D-ring or seal a. Disassemble the kickdown servo and check
down brake press- ring of the sleeve or kickdown whether the seal ring or D-ring is damaged.
ure servo piston. If it is cut or has scratches, replace the seal ring
or D-ring.
b. Looseness of valve body tighten- b. Tighten the valve body tightening bolt and
c. Functional malfunction of the c. Replace the valve body assembly.
valve body assembly
. Improper front a. Malfunction of the D-ring or seal a. Disassemble the kickdown servo and check
clutch pressure ring of the sleeve or kickdown whether the seal ring or-D-ring is damaged.
servo piston. If it is cut or has scratches, replace the seal ring
or D-ring.
valve body assembly
d. Wear of the front clutch piston or d. Disassemble the transaxle itself and check
retainer, or malfunction of the @ whether or not there is wear of the front clutch
D-ring, @ seal, ring. piston and retainer inner circumference, or
ra;;; to the figure on the next damage of the D-ring. If there is any wear or
damage, replace the piston, retainer, D-ring
and/or seal ring.
1. Improper end a. Malfunction of a D-ring @or seal a. Disassemble the end clutch and check the seal
clutch pressure ring 0, @of the end clutch or ring, D-ring of the piston, seal ring of the
O-ring @I of the pipe (Refer to the retainer, etc.; replace if there are cuts, scars,
following figure.) scratches or damage.
valve body assembly
Trouble symptom Probable cause Remedy
6. improper low- a. O-ring between valve body and a. Remove the valve body assembly and check to
reverse brake transaxle damaged or missing be sure that the O-ring at the upper surface of
pressure the upper valve body is not missin or dam-
aged; install or replace the O-ring i7 necessary.
valve body assembly
d. Malfunction of the O-ring 0 of the d. Disassemble the transaxle itself and check the
low-reverse brake piston or the O-ring for damage; replace if there are cuts,
O-ring 0 of the retainer (Refer to scars, scratches or damage.
the figure below.)
7. Improper torque a. Sticking of the damper clutch a. Check the operation of the damper clutch
converter pressure control solenoid valve (DCCSV) or system and the DCCSV.
the damper clutch control valve.
b. Clogging or leaking of the oil b. Repair or replace, as necessary, the cooler
cooler and/or piping and/or piping.
2. Damaged seal ring @of the input c. Disassemble the transaxle itself and check for
shaft (Refer to the figure below.) damage of the seal ring; replace the seal ring if
there is damage.
3. Malfunction of the torque conver- d. Replace the torque converter.
ter
@D-ring
@Seal ring
@Seal ring
-OD-ring
(@Seal ring
@O-ring
1750437
F4A33-W4A33

1. Line pressures are a. Clogging of oil filter a. Visually inspect the oil filter; replace the oil filter
all low (or high). if it is clogged.
NOTE b. Improper adjustment of oil b. Measure line pressure @ (kickdown brake
* “Line pressures” pressure (line pressure of pressure); if the pressure is not the standard
refers to oil regulator valve value, readjust the line pressure, or, if
pressure @,@I, 0, necessary, replace the valve body assembly.
0, @I and 0, in c. Functional malfunction of valve c. Replace the valve body assembly.
the “Standard oil body assembly
pressure table” on d. Looseness of valve body d. Tighten the valve body tightening bolt and
the previous page. tightening part installation bolt.
e. Improper oil pump dischange e. Check the side clearance of the oil pump gear;
pressure replace the oil pump assembly if necessary.
2. Improper reducing a. Clogging of the filter (L-shaped a. Disassemble the valve body assembly and
pressure type) of the reducing-pressure check the filter; replace the filter if it is clogged.
circuit
b. Improper adjustment of oil b. Measure the @ reducing pressure; if it is not
pressure the standard value, readjust, or replace the
valve body assembly.
c. Functional malfunction of the 2. Replace the valve body assembly.
valve body assembly
3. Improper a. Malfunction of the seal ring @, a. Disassemble the kickdown servo and check
kickdown brake D-ring @I or seal ring 0 of the whether the seal ring or D-ring is damaged.
pressure (Apply) sleeve of the kickdown servo If it is cut or has scratches, replace the seal ring
piston. or D-ring.
b. Functional malfunction of the 3. Replace the valve body assembly.
valve body assembly
4. Improper a. Malfunction of the seal ring @, 3. Disassemble the kickdown servo and check
kickdown brake D-ring @ or seal ring a> of the whether the seal ring or D-ring is damaged.
pressure (Release) sleeve of the kickdown servo If it is cut or has scratches, replace the seal ring
piston. or D-ring.
b. Functional malfunctio? of the 3. Replace the valve body assembly.
valve body assembly
5. Improper front a. Malfunction of the seal ring @, 3. Disassemble the kickdown servo and check
clutch pressure D-ring @or seal ring Q3 of the whether the seal ring or D-ring is damaged.
sleeve of the kickdown servo If it is cut or has scratches, replace the seal ring
piston. or D-ring.
b. Functional malfunction of the I. Replace the valve body assembly.
valve body assembly
c. Wear of the front clutch piston or :. Disassemble the transaxle itself and check
retainer, or malfunction of the whether or not there is wear of the front clutch
D-ring 0 or seal ring @. piston and retainer inner circumference, or
damage of the D-ring and/or seal ring. If there is
any wear or damage, replace the piston,
retainer, D-ring and/or seal ring.
*,
6. Improper rear a. Malfunction of D-ring @of rear a. Disassemble the rear clutch, check input shaft
clutch pressure clutch piston, retainer seal ring @$I seal ring, retainer seal ring, piston D ring, etc.
and seal rings @and 0 of input and replace broken or damaged parts.
shaft.
b. Functional malfunction of the b. Replace the valve body assembly.
valve body assembly
7. Improper end a. Malfunction of seal ring @or the a. Disassemble the end clutch and check the oil
clutch pressure D-ring @I and/or oil seal 0 of end seal or D-ring of the piston, seal ring of the
clutch. retainer, etc.; replace if there are cuts, scars,
scratches or damage.
valve body assembly
8. Improper low- a. O-ring between valve body and a. Remove the valve body assembly and check to
reverse brake transaxle damaged or missing be sure that the O-ring at the upper surface of
pressure the upper valve body is not missin or dam-
aged; install or replace the O-ring i7 necessary.
valve body assembly
c. Malfunction of the D-ring @of the c. Disassemble the transaxle itself and check the
low-reverse brake piston or the D-ring and O-ring for damage; replace if there
O-ring @I of the retainer are cuts, scars, scratches or damage.
9. Improper torque a. Clogging or leaking of the oil a. Repair or replace, as necessary, the cooler
converter pressure cooler and/or piping and/or piping.
b. Malfunction of the torque conver- b. Replace the torque converter.
ter
‘, :,l
OSeal ring .
f :
I
BSeal ring
EiISeal ring
eal ring
I Rear c/utch
Front clutch
@D-ring
I
I
iFAq36 1
Low-reverse brake
@Seal ring
/ OSeal ring
-ring
servo piston
TFA0362
CONVERTER STALL TEST

Stall test consist of determining maximum engine 7. Place selector lever to “R” position and perform ?+
speed obtained at full throttle in “D” and “R” stall test by the same procedure as in foregoing -,
positions. This test checks torque converter stator item.
overrunning clutch operation, and holding ability of Stall Speed Above Specification in “D”
transaxle clutches and low-reserve brake. If stall speed is higher than specification, rear clutch
Caution or overrunning clutch of transaxle is slipping. In this
During this test, make sure that no one stand in case, perform hydraulic test to locate cause of
front of or behind vehicle. slippage.
1. Check transaxle fluid level. Fluid should be at Stall Speed Above Specifjcation in “R”
normal operating temperature [70-80°C (160- If stall speed is higher than specification, front
18O”F)]. Engine coolant should also be at normal clutch of transaxle or low-reverse brake is slipping.
operating temperature [80-90°C (180- 19O”F)l. In this case, perform hydraulic test to locate cause
2. Apply chocks to both rear wheels. of slippage.
3. Attach engine tachometer. Stall Speed Below Specification in “D” and “R”
4. Apply parking and service brakes fully. If stall speed is lower than specification, insufficient
5. Start engine. engine output or faulty torque converter is sus-
6. With selector lever in “D” position, depress pected. Check for engine misfiring, ignition timing,
accelerator pedal fully to read engine maximum valve clearance etc. If these are good, torque
rpm. Do not hold throttle wide open any longer converter is faulty.
than is necessary to obtain maximum engine
rpm reading, and never longer than 5 seconds at
a time. If more than one stall test is required,
operate engine at approximatey 1,000 rpm in
neutral for 2 minutes to cool transaxle fluid
between tests.
Stall speed: 1,800-3,200 rpm
TRANSAXLE CONTROL
Selector lever operation is Incorrect adjustment of sleeve Adjust

stiff Incorrect adjustment of control cable
Excessive wear of detent plate Replace

Worn contact surfaces of pushbutton and sleeve
Starter motor does not Malfunction in inhibitor switch Replace

operate with the selector Malfunction of starter relay
lever in the “N” or “P”
position Incorrect adjustment of control cable Adjust
Will not shift to 4-speed Malfunction of OD switch Replace

CIRCUIT DIAGRAM
J/B
63
IOA
0
-----------------
- - - -
1
16 C-50 '13
2 l - AWD
z c
L
--b
s
7
1'
4 C-58 13 C-67
El
THEFT-ALARM
CONTROL UNIT I
I
INHIBITOR
SWITCH
B-25
r 1 3
:-
xl 71
03
'OU'EiR
aPPLl I
4
STARTER MOTOR
L--
X35-AC-U0705-NC
IGNITION IGHT
SWITCH(IG2)
0
?
c;3
_----__---___-. E
-7r
0
1UA
\I
Ej C-53mJ 3 19 ~lo~ll~l2~la~lq1qls
ca (LB)
POWER/ A/T SELECTOR

ECONOMY LEVER POSITION
;$;;E OVER "r- ILLUMINATION
LIGHT
D-19 A, .
1 2
$
l!i3Fl
3453
,F
WITHOUT
AU;iUi~;UISE
f---h
I
s
P5I11
AUTO-
CRUISE
CONTROL
LIEI UNIT
______--___---__--------
4
g F
C-61 -t
57
_______-__-----_---_ -----
J/B
Remark
**Mark i n d i c a t e s t h e oPtional w i r i n g
FEI~~I;S f o r auto-cruise c o n t r o l
AIR CONDITIONER POWE

CONTROL UNIT IGNI TIO1 TRAN STOR
CRC
FILTER
B-11
ON+OFF:
2700kP.%(384Psl)
OFF+ON:
- /
1. 8L
ENGINE
t
3J 29
I GtD G:D GB “tD----
‘----_ I - - - - - -----
06 101 02 1
NON-
TURBC
$;X;kERATOR J Pz / 0 9
SELF
SWITCH -DIAGNOSIS
CONNECTOR
WITH c-30
WITHOUT FRONT SIDE
,$J;$JR~;UISE 1 AUTO-CRUISE
. CONTROL p&a-q _1 ---- 2_---- I.----,
E%ERSE
p!!iQq
I A
I IL- B
I I L.&.j IUK 1
mB
m m B-24 4-SPEED AUTOMATIC
TRANSAXLE SOLENOID VALVE
CL CL
x
- 1- Remark
*%Mark i n d i c a t e s t h e o p t i o n a l wlrlns
fg h a r n e s s f o r a u t o - c r u i s e c o n t r o l system.
KX35-AC-U0705A-NC
-------
r irII
---_-____-_--
1.8L ENGINE 2.0L DOHC ENGINE
C-66
a
1 c-47
B l ’
J/B
\/
2 c-50
2-i
,
7 C-67
ID;E
SWITCH
B-05 q ’
I
,21
i -I+ -id-
* *
r -
--
31 i-ET
kxrn ? c C
-- --. - -
II
h
5- 59 D-06
I
I,1,. 1 .-- - - .--
1 $~#~OWN COMBINATION i
METER
A-37 SWITCH D-05 m 3 c! C
I@JJ , A-38
NON- IBI I 1
- -
- TURBO - - TURBO
‘-- -
- - - - - -I
-u-u u-u
J-r
PULSE
,4/s&q 4 c-49 12 GENERATOR
a4
ED
11 12 “p A-51 m
cu
:
Ii
E.L.C. 4-SPEED AUTOMATIC TRANSAXLE CONTROL COMPONENTS LAYOUT
Name Symbol Name Symbol
Diagnosis connector F Pulse generator B A
Engine control unit I Solenoid valves C
Oil temperature sensor D Throttle position sensor B
Power (PWR)/Economy (ECO) select switch G Transaxle control unit H
Pulse generator A A Vehicle-speed sensor E

1
NOTE
1. The “Name” column is arranged in alphabetical order.
2. Refer to GROUP 14-On vehicle inspection of MPI components for installation position of H throttle position
sensor.
1.8L Engine 2.0L DOHC Engine

select switch
AUTOMATIC TRANSAXLE - s ervice Adjustment Procedures 21-209
N21FB6E
TRANSAXLE FLUID LEVEL INSPECTION

1. Drive until the fluid temperature reaches the usual tem-
perature [70-80°C (160- 18O”F)I.
torque converter and hydraulic circuit with fluid, then place
lever in “N” Neutral position.
09Pooi a dipstick. Then take out the dipstick and check the condition
of the fluid.
conditions.
l If there is a noticeably great amount of metal particles in
the fluid.
with this range. 5. Check to see if fluid level is in “HOT” range on dipstick. If
fluid level is low, add automatic transaxle fluid until level
reaches “HOT” range.
09POOll Transaxle fluid: MOPAR ATF PLUS (Automatic trans-
mission fluid type 7176) or Dia ATF SP
or equivalent
Low fluid level can cause a variety of conditions becaljse it

allows pump to take in air along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressures will be erratic, causing delayed shift,
slippy clutch and brakes, etc.
cause the same conditions which occur with low fluid level,
TWO382 resulting in accelerated deterioration of automatic transaxle
fluid.
In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch,
escaping from transaxle vent where it may be mistaken for
a leak.
TRANSAXLE FLUID REPLACEMENT N21FCBAa

TRANSFER OIL LEVEL INSPECTION NZlFXAA
Transfer oil level inspection is the same as for the manual

transaxle transfer.
TRANSFER OIL REPLACEMENT NZlFYAFa
Transfer oil replacement is the same as for manual transaxle

transfer.
21-210 AUTOMATIC TRANSAXLE - Service Adjustment Procedures
SELECTOR LEVER OPERATlON CHECK NZlFlAE
1. Shift selector lever to each range and check that lever +

moves smoothly and is controled. Check that position
indicator is correct. -L*
2. Check to be sure the selector lever can be shifted to each
position (by button operation as shown in the illustration).
3. Start the engine and check if the vehicle moves forward
when the selector lever is shifted from N to D, and moves
backward when shifted to R.
4. When the shift lever malfunctions, adjust control cable
and selector lever sleeve. Check for worn shift lever
assembly sliding parts.
NOTE
To move the selector lever from the “P” position to any
other position, first turn the ignition key to any position
OSA0141
other than “LOCK (OFF)” and depress the brake pedal.
ti Button pressed (while brake
pedal is depressed)
l Button not pressed
9 Button pressed
KEY INTERLOCK MECHANISM CHECK NZlFUAA
1. Completely stop the vehicle and switch OFF the engine

before making the check.
2. Check to be sure that, under the following conditions, the ?c
select lever cannot be moved from the “P” position to any ~.‘,
other position.
Also check, at the same time, that the button cannot be
pressed.
Ignition key position: “LOCK (OFF)“, or removed
Brake pedal: Depressed
3. Check to be sure that, under the following conditions, the

select lever can be moved from the “P” position to any
other position.
Press the button a few times and check to be sure that the
select lever moves smoothly.
Ignition key position: “ACC”
Brake pedal : Depressed
Button : Pressed
4. Check to be sure that, at all positions of the select lever

(other than “P”), the ignition key cannot be turned to the
“LOCK (OFF)” position.
Check to be sure that the ignition key smoothly turns to the
“LOCK (OFF)” position when the select lever is then set to
the “P” position and the button is released.
5. If a malfunction is discovered when following the above ,”
checking procedures, either adjust or check the key
interlock cable mechanism. (Refer to P.21-220.)
AUTOMATIC TRANSAXLE - Service Adjustment Procedures 21-211
SHIFT LOCK MECHANISM CHECK N21FVAA
select lever cannot be moved from the “P” position to any
other position.
Brake pedal: Not depressed
Button: Pressed
select lever can be moved smoothly from the “P” position
to other position.
09A0146 OQMOO45
Brake pedal: Depressed
Button: Pressed
select lever can be moved smoothly from the “R” position
to the “P” position.
Brake pedal: Released
Button: Pressed
4. If a malfunction is discovered when following the above
checking procedures, either adjust or check the shift lock
cable mechanism. (Refer to P.21-220.)
<Non-Turbo> <Turbo> INHIBITOR SWITCH ADJUSTMENT NZlFKAJ
INHIBITOR SWITCH
1. Place selector lever in “N” (Neutral) position.
2. Place manual control lever in “N” (Neutral) position.
3. To adjust, rotate the switch body so that the manual control
lever 5 mm (2 in.) hole and the switch body 5 mm (.2 in.)
hole are aligned.
4. Tighten the mounting bolts of the inhibitor switch body to
control lever the specified torque. At this time, take care to prevent
control lever dropping the switch body.
5 mm
Specified torque: lo-12 Nm (7-9 ftlbs.)
Section A-A (2 in.) Manual
control
lever
Switch body
5. Loosen the nut shown in the figure, and lightly pull the end
of the transaxle control cable in the “F” direction by hand.
6. Tighten the nut to the specified torque.
Specified torque: IO-14 Nm (7-10 ftlbs.)
7. Check that the selector lever is in “N” position.
8. Check that it securely operates and functions on the
transaxle side in the range which corresponds to each
position of the selector lever.
21-212 AUTOMATIC TRANSAXLE - Service Adiustment Procedures
KICKOOWN SERVO ADJUSTMENT NZlFRAB
1. Completely remove all dirt and other materials adhered G+

around the kickdown servo switch. -i-s-
2. Remove the snap ring.
3. Remove the kickdown servo switch.
4. To prevent rotation of the piston, engage the pawl of the

special tool into the notch of the piston, and using the
adapter, fix the piston as shown in the left.
Caution
1. Don’t press in the piston with the special tool.
2. When mounting the adapter on the transaxle case,
tighten it by hand. Don’t apply much torque.
5. Loosen the lock nut to before the V groove of the adjusting

rod, and tighten the special tool (inner) until it contacts the
lock nut.
1750464
6. Engage the special tool (outer) on the lock nut.

Rotating the outer cylinder counterclockwise and the inner
cylinder clockwise, lock the lock nut and special tool (inner).
7. Attach the torque wrench to the special tool (inner), and

repeat “tightening” and “returning” at a torque of IO Nm
(7.2 ft.lbs.) two times. Then, tighten it to a torque of 5 Nm
(3.6 ftlbs.). Then, back off the special tool (inner) 2 to 2%
turns.
*
. .
AUTOMATIC TRANSAXLE - Service Adjustment Procedures 21-213
8. Engage the special tool (outer) on the lock nut.
Rotating the outer cyliner clockwise and the inner cylinder
counterclockwise, unlock the lock nut and special tool
(inner).
Caution
When unlocking the lock, apply equal force to both
tools.
9. Tighten the lock nut by hand until the lock nut contacts the
piston. Then, using the torque wrench, tighten to the
specified torque.
Lock nut: 25-32 Nm (18-23 ft.lbs.)
Caution
If it is rapidly tightened with the socket wrench or
torque wrench, the lock nut and adjusting rod may
rotate together.
10. Remove the special tool which fastens the piston.
Attach the plug to the outlet of the low reverse pressure.
LINE PRESSURE ADJUSTMENT N2lFSABl
1. Drain out the automatic transaxle fluid.

2. Remove the oil pan.
3. Remove the oil filter.
4. Remove the oil-temperature sensor.
5. Press the solenoid valve harness grommet and connector
into the transaxle case.
6. Remove the valve body assembly. The manual valve can

come out, so be careful not to drop it.
7. Turn the adjustment screw of the regulator valve and adjust
so that the line pressure (kickdown brake pressure) a,
becomes the standard value.
When the adjustment screw is turned to the clockwise, the L
line pressure becomes lower; when it is turned to
counter-clockwise, it becomes higher.
Standard value: 870-890 kPa (124-127 psi)
Oil pressure change for each turq of
adjustment screw: 38 kPa (54 psi)
8. Check to be sure that the O-ring is installed on the upper

surface of the valve body at the place shown in the figure.
9. Replace the O-ring of the solenoid valve harness grommet
with a new one.
10. Insert the solenoid valve harness grommet in the axle case.
'50157
1 11. Install the valve body and oil temperature sensor, and then
tighten valve body assembly mounting bolts (IO pieces) to
IO-12 Nm (7.5-8.5 ft.lbs.).
A: 18 mm (.709 in.) long +-t
B: 25 mm (.984 in.) long --,,
C: 40 mm (1.575 in.) long
12. Install the oil filter.
13. Install a new oil pan gasket and oil pan.
14. Pour in the specified amount of Automatic transaxle fluid.
15. Make the oil pressure test. Readjust if necessary.
F4
REDUCING PRESSURE ADJUSTMENT NZlFTAC
(If the multi-use tester is not available)

1. Remove parts up to the oil filter in the same way as for
adjustment of the line pressure. The valve body need not
be removed. +%
2. Turn the adjustment screw of the lower valve body and _
adjust so that the reducing pressure is the standard value.
When the adjustment screw is turned to the right, the
reducing pressure becomes lower; when it is turned to the
left, it becomes higher.
AUTOMATIC TRANSAXLE - Service Adjustment Piocedures 21-215
NOTE
When adjusting the reducing pressure, aim for the center
value (425 kPa, 60 psi) of the standard value allowance.
Standard value: 425+ 10 kPa (60+ 1 psi)
Oil pressure change for each turn of
adjustment screw: F4A22 . . . . . . ;...........,.. 22 kPa (3.1 psi)
F4A33mW4A33 . . . . . . 86 kPa (12.2 psi)
3. Install the oil filter and oil pan in the same way as for
adjustment of the line pressure.
4. Make the oil pressure test. Readjust if necessary.
THROTTLE-POSITION SENSOR ADJUSTMEN&

DRIVE SHAFT OIL SEALS REPLACEMENT NZWWA,

(1) Disconnect the drive shaft from the transaxle.
(Refer to GROUP 2-Drive Shaft.)
OQK567
OSKS68
(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
(4) Apply a coating of the transaxle fluid to the lip of the oil seal.
Transaxle fluid: MOPAR ATF PLUS (Automatic trans-

mission fluid type 7176) or Dia ATF SP
or equivalent
Mb998325
160024
SPEEDOMETER CABLE REPLACEMENT ,

N21FEAK2
1. Correctly insert the adapter into the instrument panel, and +

fasten the new speedometer cable. t,
I 16A0905
2. Install the grommet so that, as shown in the illustration, the

cable attachment is positioned upward.
Caution
1. The cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
2. The arrangement of the speedometer cable should
be such that it does not interfere with other parts.
3. At the transaxle end of the speedometer cable, the key

joint should be inserted into the transaxle, and the nut
should be securely tightened.
Caution “cc
If the cable is not correctly and securely connected, it
may cause incorrect indication by the speedometer, or
abnormal noise. Be sure to connect it correctly.
AUTOMATIC TRANSAXLE - Transaxle Control 21-217
TRANSAXLE CONTROL
dl_i REMOVAL AND INSTALLATION NZlub-
lo-14 Nm
7-10 ft.lbs.
i 28
-.
4-6 Nm
y-14 Nm
7-10 ft.lbs.
Transaxle control cable and selector lever

assembly removal steps 18. Key interlock cable (selector lever
assembly side)
1. Plug 23. S$i; lock cable (selector lever assembly
2. Side cover (B)
3. Power (PWR)/Economy (ECO) switch 26. Snap pin
4. Side cover(B) 27. Clip
5. Cover(B) 28. Adjusting nut
6. Cup holder l 4 29. Clip
7. Carpet ++ 30. Transaxle control cable
8. EZrreTstion of floor console wiring 31. Selector lever assembly
9. Guide ring <Vehicles for U.S.>
IO. Shoulder belt <Vehicles for U.S.> zykeverse the removal procedures to reinstall.
11. Floor console (2) l + : Refer to “Service Points of Installation”
17. Snap pin
2l-218 AUTOMATIC TRANSAXLE - Transaxle Control
724
16
9-14 Nm
7-10 ftlbs.
7 \\
4-6 Nm
3-4 ft.lbs.
3-4 ft.lbs.
‘17 09A0138
18'
Key interlock cable removal steps Shift lock cable removal steps
1. Plug 1. Plug
2. Side cover(B) 2. Side cover(B)
3. Power (PWR)/Economy (ECO) switch 3. Power (PWR)/Economv (EC01 switch
4. Side cover(B) 4. Side cover(B) ’
5. Cover (B) 5. Cover(B)
6. Cup holder 6. Cup holder
7. Carpet 7. Carpet
8. ;ir;eystion of floor console wiring 8. Connection of floor console wiring
harness
9. Guide ring <Vehicles for U.S.> 9. Guide ring <Vehicles for U.S.>
10. Shoulder belt <Vehicles for U.S.> 10. Shoulder belt <Vehicles for U.S.>
11. Floor console. 11. Floor console
12. Plug 12. Plug
13. Knee protector assembly 13. Knee protector assembly
14. Hood lock release handle 14. Hood lock release handle
15. Lap cooler duct and shower duct (L.H.) 15. Lap cooler duct and shower duct (L.H.)
16. Column cover 19. Clamp
17. Snap pin l + 23. :izs lock cable (selector lever assembly
l + 18. Key interlock cable (selector lever
assembly side) 24. Split pin
19. Clamp 25. Shift lock cable (brake pedal side)
20. Cover
l + 21, Key interlock cable (steering lock
assembly side)
e+ 22. Slide lever
NOTE
(3) Be sure to connect and adjust the transaxle control
cable before connecting the key interlock cable or shift
lock cable
AUTOMATIC TRANSAXLE - Transaxle Control
INSPECTION N2ucAtl
l Check the control cable for function and for damage.
8 Check the bushing for wear or damage.
POWER (PWR)/ECONOMY (ECO) SWITCH

Check for continuity between terminals when the switch is OFF
and when ON.
Terminal 1 I I I I I ’
NOTE
09AOll5
O-O indicates that there is continuity between the terminals.
OVERDRIVE CONTROL SWITCH

Check for continuity between terminals when the switch is OFF
and when ON.
ON (Overdrive activation) 0 0
OFF (Overdrive non-activation) 0 3

09AOO39
NOTE
0-O indicates that there is continuity between the terminals.
<Non-Turbo> <Turbo> SERVICE POINTS OF INSTALLATION N21lDAO

Neutral position
30. INSTALLATION OF TRANSAXLE CONTROL CABLE
Move the selector lever and the inhibitor switch to the “N”
position, and install the transaxle control cable.
29. INSTALLATION OF CLIP
When connecting the control cable to the transaxle mount ,-
bracket, install the clip until it contacts the control cable, in ,”
the position shown in the figure.
:le mot Jnt l ADJUSTMENT OF TRANSAXLE CONTROL CABLE

Refer to the section concerning adjustment of the inhibitor
\\ \ 09R0058 switch. (Refer to P.21-211.)
23. INSTALLATION OF SHIFT LOCK CABLE (SELECT LEVER

ASSEMBLY SIDE)
(1) Move the select lever to the “R” position.
(2) Clamp the shift lock cable.
(3) Connect the shift lock cable to the select lever
assembly, and temporarily tighten the nut.
(4) Slide the shift lock cable so that the distance between
the select lever assembly’s detent pin and the end of
the shift lock cable is the standard value, and then
09AO143 tighten the nut at the specified torque.
Standard value (A): l-4 mm (.04-.I5 in.)
(5) After connecting the shift lock cable, check the shift
lock mechanism. (Refer to P.21-211.)
22. INSTALLATION OF THE SLIDE LEVERI21. KEY INTER-
LOCK CABLE (STEERING LOCK ASSEMBLY SIDE)
(1) With the ignition key either at the “LOCK” position or
removed, install the slide lever to the key cylinder.
/’ ’ Cover
(2) Connect, as shown in the figure, the key interlock cable
Cover to the slide lever and the key cylinder.
\ (3) Apply a light coating of multipurpose grease where
Key interlock cable OSA0125
(4) Install the key interlock cable.
OSAO126
18. INSTALLATION OF KEY INTERLOCK CABLE (SELECT

LEVER ASSEMBLY SIDE)
(1) Move the select lever to the “P” postion.
(2) Connect the key interlock cable to the select lever
assembly’s lock cam. Be sure that the spring installed
to the key interlock cable is as shown in the figure. *
(3) While gently pressing the lock cam in the F direction, -
tighten the nut to secure the key interlock cable.
(4) After connecting the key interlock cable, check the key
interlock mechanism. (Refer to ‘P.21-210.)
DISASSEMBLY AND REASSEMBLY (SELECT LEVER ASSEMBLY) N210E--
2.0 Nm or more
1.4 ft.lbs. or more
2.0 Nm or more
1.4 ft.lbs. or more
/ 1.0-2.0 Nm
0.7-1.4 ft.lbs.
14-20 Nm
lo-14 ft.lbs.
Disassembly steps OSA0135
4+ 1. Overdrive control switch connector *4 13. Sleeve

2. Cover 14. Lever assembly
3. Selector knob I)+ 15. Bushing
:: 4. Overdrive control switch button 16. Pipe
5. Overdrive control switch 17. Split pin
6. Pin l * 18. Lock cam
l * 7. Pushbutton 19. Bracket assembly
ea 8. Spring
9. Indicator panel NOTE
10. Slider (I) Reverse the disassembly procedures to reassemble.
11. indicator panel lower (2) ++ : Refer to “Service Points of Disassembly”.
12. Socket assembly (3) l + : Refer to “Service Points of Reassembly”.
SERVICE POINTS OF DISASSEMBLY N21OFAC
1. REMOVAL OF OVERDRIVE CONTROL SWITCH CON-

NECTOR
Disconnect the overdrive control switch connector and
then remove the terminal from the overdrive control
switch connector.
Sciewdriver
21-222 AUTOMATIC TRANSAXLE - Transaxle Control
4 . R E M O V A L O F OVERDRJVE C O N T R O L SWlTCH
BUlTON /5. OVERDRIVE CONTROL SWITCH
(1) Using the flat-tip screwdriver, remove the overdrive -r,
J%
control switch button.
(2) Pressing the switch, remove the overdrive control
switch.
INSPECTION N21ocuD
l Check the detent plate for wear.

l Check the bushing for wear or damage.
OSAOO88 l Check the spring for damage or deterioration.
SERVICE POINTS OF REASSEMBLY NZlOHAM
18. APPLICATION OF GREASE TO LOCK CAM

Lock Farn
Apply a coating of multipurpose grease to the sliding part of
the bushing.
09A0136
15. APPLICATION OF GREASE TO BUSHING

Apply a coating of multipurpose grease to the sliding part of
the bushing.
09ROll6
13. INSTALLATION OF SLEEVE

Apply grease
here. (1) Place the shift lever in the “N” position, and then turn
the sleeve so that the clearance between the sleeve
I
Sleeve
and the lever assembly end is within the standard
value.
Lever Standard value (A): 15.2-15.9 mm (.598-.625 in.)
/ assembly
(2) Apply a coating of multipurpose grease to the surface of
the sleeve.
09AOO43
L J No. 2525035 or equivalent
I 8. APPLICATION OF GREASE TO SPRINGI7. PUSHBUT-
TON
Apply multipurpose grease at the places shown in the
figure.
Grease: MOPAR Multi-mileage Lubricant Part Y
No. 2525035 or equivalent ‘,#
09AOO49
AUTOMATIC TRANSAXLE - Transaxle Oil Cooler Hoses 2 I*-223
TRANSAXLE OIL COOLER HOSES <NON-TURBO> NZlSA-A
3-5 Nm
2-4 ftlbs.
4-6 Nm
3-4 ftlbs.
09AOO41
Removal steps NOTE
1. Hose clamp (1) Reverse the removal procedures to reinstall.
4* 2. Oil cooler hose assembly (2) 4e : Refer to “Service Points of Removal”.
SERVICE POINTS OF REMOVAL NZISSAD
2. REMOVAL OF OIL COOLER HOSE ASSEMBLY

Caution
1. Take care not to spill the transaxle fluid when
removing components.
2. After removing the oil cooler hose assembly, plug
so that foreign materials cannot enter the transaxle.
INSPECTION m1scAF
l Check the hose for crack, damage and clog.
l Check for rusted or clogged radiator oil cooler.
21-224 AUTOMATIC TRANSAXLE - Transaxle Oil Cooler
TRANSAXLE OIL COOLER <TURBO> N21SA-B
REMOVAL AND INSTALLATION Pre-removal Operation

eDraining of Automatic Transaxle Fluid
&
.
(Refer to GROUP O-Maintenance Service.) -=-.

@Removal of Air Cleaner
(Refer to GROUP II-Air Cleaner.)
l Removal of Radiator Reserve Tank
@Removal of Front Bumper
(Refer to GROUP 23-Front Bumper.)
@Removal of Air Guide Duct
(Refer to GROUP 23-Loose Panel.)
*Installation of Air Guide Duct

(Refer to GROUP 23-Loose Panel.)
*Installation of Front Bumper
OQA0169 (Refer to GROUP 23-Front Bumper.)
@Installation of Radiator Reserve Tank
30-35 Nm (Refer to GROUP 7-Radiator.)
22-25 ft.lbs. *Installation of Air Cleaner
(Refer to GROUP II-Air Cleaner.)
3-5 N m
1 /I /1’-
/ I -
l Filling of Automatic Transaxle Fluid
2 - 4 ftlbs. ‘\
8-12 Nm m2
6 - 8 ft.lbs.
\ \
3-5 N m
2 - 4 ftlbs.
8-12 Nm
6 - 8 ft.lbs.
Removal steps
1. Eye bolts ‘8-12 Nm
2. Gasket OBAOl70
6 - 8 ftlbs.
3. Bracket
4. Transaxle oil cooler NOTE
5. Oil cooler feed tube (1) Reverse the removal procedures to reinstall.
7: ~i&~oler return tube (2) ++ : Refer to “Service Points of Removal”.
+e l + 8. Oil cooler hose (4) m : Non-reusable parts
SERVICE POINTS OF REMOVAL NZlSBAF
8. REMOVAL OF OIL COOLER HOSE ASSEMBLY

Refer to P.21-223.
INSPECTION N2lSCAG
l Check the hose and tube for crack, damage or clog.

l Check for rusted or clogged oil cooler.
l Check the eye bolt for clogging or deformation.
SERVICE POINTS OF INSTALLATION N2lSDAC ‘-+

_
8. INSTALLATION OF OIL COOLER HOSE
Oil cooler hose There are 2 types of oil cooler hoses, a long one and a short
Oil cooler return tube one. Connect the long one to the oil cooler return tube and
09A0171 the short one to the oil cooler feeder tube.
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22> 21"225
TRANSAXLE ASSEMBLY <F4A22> N2ll.A.A
,--. REMOVAL AND INSTALLATION

@Removal of Battew @Installation of Air Cleaner
aDraining of Transaxle Fluid (Refer to GROUP 11 -Air Cleaner.)
(Refer to GROUP O-Maintenance Service.) @Installation of Battery
aRemoval of Air Cleaner *Supplying of Transaxle Fluid
(Refer to GROUP 11 -Air Cleaner.) (Refer to GROUP O-Maintenance Service.)
27-34 Nm 60-80 Nm
20-25 ftlbs. 43-58 ft.lbs.
60-80 flrn /
43-55 Nm
11
31-40 ft.lbs.- \
/
/ \
-LTT \.
q 30-35 Nm
30-35 Nm AI ft.lbs.
2 2 - 2 5
22-25 klbs.
09A0109
Removal steps
1. Adjusting nut
l * 2. Connection for transaxle control cable
3. Connection for solenoid connector
4. Connection for inhibitor switch connector
5. Connection for pulse generator connector
6. Connection for kickdown servo switch
connector
7. Connection for oil temperature sensor
connector
8. Connection for speedometer cable $?everse the removal procedures to reinstall.
9. Connection for oil cooler hose (2) l 4 : Refer to “Service Points of Installation”.
10. Starter motor
11. Upper coupling bolt for transaxle
assembly and engine assembly
12. Transaxle mount bracket
21-226 AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22>
46-53 Nm
33-38 ftlbs.
7-10 ft.lbs.
30-35 Nm
22-25 ftlbs. IO-12 Nm
7-9 ftlbs. I
18m
16
13. Under guard

14. Cotter pins
15. Connection for tie rod end
16. Connection for lower arm ball joint
17. Connection for drive shaft
18. Circlip
20. Special bolts NOTE
21. Lower coupling bolt for transaxle (1) Reverse the removal procedures to reinstall.
assembly and engine assembly (2) l * : Refer to “Service Points of Removal”.
22. Transaxle assembly (3) m : Non-reusable parts
AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A22>
SERVICE POINTS OF REMOVAL N2llEAK

knuckle.
Caution
nearby part.

from the knuckle.
Caution
nearby part.
MB991 113 -
12K513

(1) Insert a pry bar between the transaxle case and the
transaxle.
Caution
2. Do not insert the pry bar so deep as to damaged
Transaxle the oil seal.
Pry bar *
llK611 (2) Keep the removed drive shaft as far away from the
etc.) the T.J. to the body so that it does not fall.
20. REMOVAL OF SPECIAL BOLTS

(1) Remove the three special bolts connecting the con-
verter to the drive plate.
NOTE
To remove the special bolts of torque converter, turn
engine crankshaft with a box wrench to bring one of
the bolts to the position appropriate for removal. After
removing the bolt, turn the crankshaft in the same
manner as above and remove all remaining bolts one
after another.
(2) After removing the special bolts, push the torque
converter toward transaxle so that it does not remain on
the engine side.
SERVICE POINTS OF INSTALLATION N2lWAY
2. CONNECTION OF TRANSAXLE CONTROL CABLE

Refer to P.21-211.
DISASSEMBLY AND REASSEMBLY <F4A22> NZlLEBB
18. Thrust bearing #8

19. Kickdown band
20. Kickdown drum
21. Snap ring
22. Center support
23. O-ring
24. Wave spring
25. Return spring
20 \23
17
\
18 1. Torque converter
8. Front clutch assembly
9. Thrust race #3
10. Thrust bearing #4
11. Thrust washer #2
26.
27.
28.
29.
Pressure plate
Brake disc
Brake plate
Reaction plate
2. Converter housing 12. Rear clutch assembly 30. Reverse sun gear
3. Gasket 13. Spacer 31. Thrust bearing #9
4. Oil pump 14. Differential 32. Thrust race # 10
5. O-ring 15. Thrust bearing #6 33. Forward sun gear
6. Gasket 16. Clutch hub 34. Planetary carrier
7. Thrust washer #l 17. Thrust race #7 35. Thrust bearing # 12
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22> B-229
ln ~19 Nm
bs.
36. Pulse generator 17-21 Nm
37. Spring washer 6 - 8 Nm
38. Control lever 5 - 6 ft.lbs.
39. Clamp
40. Inhibitor switch
6 45
-I
IO-12 N m ,----IT
7.3-8.6 ftlbs. -39
46 TV -- .-.
AR-M N~J
35-43 ft.iIbs.
b??io
\h r 20-35 N m \ \ ,,,-e30 Nm
iii-26 ft.lbs. ,i7 56 ._.. .__ ._..v.
ldr;-11% f-klhs.
-
-67
74 7I %!%t.lbs. 3 <
-69
TFA0505
8 0 - 73. Drain plu! g

lo-12 Nm 74. O-ring
v7.3-8.6 ftJbS- 75.
-^ Setscrev
^ V
/8. u-nng
77. Detent ball
20-27 N m 30-35' N m 60. Kickdown servo piston 78. Detent seat
15-16 ft.lbs- 22-26 ftlbs. 61. Spring 79. Detent spring
41. Oil temperature sensor I 62. Anchor rod 80. Sprag rod support
42. End clutch cover 51. Snap ring 63. Output flange 81. Parking sprag rod
43. O-ring 52. Lock plate 64. Transfer shaft 82. Control shaft
44. Bearing 53. Idler gear shaft 65. Outer race 83. D-ring
45. End clutch 54. Bearing inner race 66. Gasket 84. Transfer shaft cover
46. Thrust washer 55. Idler gear 68. Valve body assembly 85. Lock nut
47. End clutch hub 56. Bearing inner race 69. Clamp 86. Driven gear
48. Thrust bearing # 13 57. Spacer 70. Gasket 87. Outer race
49. End clutch shaft 58. Snap ring 71. Oil pan 88. Spacer
50. Bearing retainer 59. Kickdown servo switch 72. Gasket 89. Transaxle case
-2.rt-2-30 ~~ AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22>
DISASSEMBLY NZlLEAl
;haft
1. Clean away any sand, mud, etc. adhered around the .+.
transaxle.
2. Place the transaxle assembly on the workbench with the oil --’
pan down.
3. Remove the torque converter.
4. Measuring input shaft end play before disassembly will
usually indicate when a thrust washer change is required
(except when major parts are replaced). Thrust washers are
located between reaction shaft support and rear clutch
1770083
retainer, and between reaction shaft support and front
clutch retainer.
Mount a dial indicator to converter housing with the Dial
Indicator Support. Make sure that the indicator plunger is
seated against end of input shaft.
When checking end play, pull out or push in the input shaft
with pliers. Be careful not to scratch the input shaft. Record
indicator reading for reference when reassembling transax-
le.
5. Remove the pulse generator “A” and “B”
6. Remove manual control lever, then remove inhibitor

switch.
7. Remove snap ring then remove kickdown servo switch.

AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22> 21-237
8. Remove the oil pan and gasket.
9. Remove the oil filter from the valve body.
10. Remove the oil-temperature sensor installation bolt; then,

sensor after removal from the bracket, pull out from the connector
side.
11. Insert the solenoid valve harness grommet and connector
into the transaxle case.
1750428
12. Remove 10 bolts and remove valve body.
13. Remove the end clutch cover mounting bolt the cover
holder, and the end clutch cover.
14. Remove the end clutch assembly.
15. Remove the thrust plate.
16. Remove the end clutch hub and thrust bearing.
17. Pull out the end clutch shaft.
18. Remove 13 bolts and remove converter housing.

19. Remove 6 bolts, and attach the special tools and remove oil
pump assembly.
20. Remove the spacer and the differential assembly.
21. Remove the thrust washer #I
22. Pull up the input shaft, and then remove the front clutch
assembly and the rear clutch assembly together.
23. Remove the thrust bearing #6.

24. Remove the clutch hub.
25. Remove the thrust race #7 and bearing #8.
26. Remove the kickdown drum.
27. Remove the kickdown band.
28. Using the valve spring compressor and special tool, push in
the kickdown servo and remove the .snap ring.
29. Remove the kickdown servo piston and spring.
Anchor rod
30. Remove the anchor rod.
32. Mount the special tool on the center support and remove
the center support from the case.
33. Remove reverse sun gear thrust bearing #9, thrust race
Reverse sun gear e
# 10 and forward sun gear together.
-Forward sun gear

34. Remove planet carrier assembly and thrust bearing #12.
6,
9-s
750174
35. Remove the wave spring, return spring, reaction plate,

brake discs, and brake plates.
36. Since screw lock paste is coated on the screw threads, tap
the screw head for easier removal.
37. Using an impact driver, loosen the screw.
If an impact driver is not available, use a punch or

something similar.
AUTOMATIC TRANSAXLE - Transaxle Asscimblv <F4Ai2> 21-237
38. Remove idler shaft lock plate.
39. Loosen transfer idler shaft with special tool.
40. Pull out transfer idler shaft. Remove transfer idle gear
bearing inner races (2 pieces) from inside of case.
41. Remove the spacer.
42. Remove snap ring from bearing.

21-238 AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A22>
43. Remove internal gear, output flange, transfer drive gear and
bearing as assembly from case.
*
44. Remove the transfer shaft cover
Transfer shaft cover

TFAOMS I
45. Stand the transfer shaft lock nut rotation stopper up.
46. Fix the transfer shaft converter housing side.
47. Remove the locking nut.
NOTE
The lock nut is left-hand threaded.
AUTOMATIC TRANSAXLE - Transaxle Assemblv 44A22> 21-239
48. Press out the transfer shaft to the converter housing side.
49. Using the special tool, pull the bearing from the transfer
shaft.
1770042
50. Using the special tool, pull the bearing from the transfer
driven gear.
51. Using a screwdriver, remove the outer race.
1770106
52. Remove two bolts and sprag rod support.

21-240 AUTOMATIC TRANSAXLE - Transaxle Assemblv <FQA22>
53. Remove the set screw and the manual control shaft
assembly. Remove the steel ball, the seat and the spring
together at this time. /4~
c..
Set screw
Detc
Manual control
Se shaft
DktenFplate
1750441
REASSEMBLY NZlLFAJ
1. Before assembly of the transaxle, measure the end play of

the low-reverse brake, and select a pressure plate to be
used so that the end play will be the standard value.
(1) Install the brake reaction plate, brake plate and brake
disc to the transaxle case.
Caution
If new brake discs are used, be sure to immerse
them in ATF for two hours or longer.
(2) Install the appropriate pressure plate and then install

the return spring.
Caution
Be sure that the return spring is installed so that it fi
faces in the correct direction. Le
Pressire plate \
Brake disc 1750208
(3) Apply a coating of petrolatum to the wave spring and

attach it to the center support.
1750193
(4) Install the special tool to the center support.

AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A22> 27-241
(5) Install the snap ring.
(6) Install the special tool and a dial gauge at the rear side
of the transaxle case.
Caution
Install the dial gauge so that it contacts the brake
reaction plate at a right angle from the transfer idler
shaft hole.
(7) Using a manual pump, pump air in from the position

shown in the illustration; then read the indication of the
dial gauge, and select the pressure plate that will
provide the standard value.
(8) When the pressure plate is completely selected,
remove the assembled part.
2. Install the parking sprag rod to the manual control shaft.

O-ring groove Then, as shown in the figure, press into the transaxle case.
At this time, do not install O-ring (larger one of two O-rings)
Set screw hole on manual control shaft.
Manual control
shaft NOTE
If installed before inserting shaft, the O-ring will interface
with shaft set screw hole.
1750442
3. After installing new O-ring on manual control shaft, draw
shaft back into case, then install set screw and gasket. Also
install detent steel ball, seat and spring at the same time.
Manual control
4. Install sprag rod support and tighten two bolts.

Sprag rod support bolts: 20-27 Nm (15-19 ftlbs.)
5. Using the special tool, tap in the bearing outer race.
6. Press-fit the bearing inner race to the transfer djrven gear

and press-fit the bearing outer race to the transaxle end
clutch side.
1770056
7. Press-fit the bearing inner race to the transfer shaft, and
press-fit the bearing outer race to the transaxle case
converter housing side.
1770057
8. Attach the transfer shaft to the transaxle case.
9. Install the special tool to the transaxle case to support the

transfer shaft.
r
10. Insert the thickest 1.80 mm (.0709 in.) spacer.
11. Using a press, press-in the transfer driven gear.

12. After removing the special tool, affix the converter housing
side of the transfer shaft.
P-
13. Tighten the lock nut to the specified torque.
Transfer lock nut: 200-230 Nm (145-166 ft.lbs.)
14. Measure the transfer shaft end play and select and reinstall
the spacer which provides the specified end play.
Transfer shaft end play: O-0.025 mm (O-.0010 in.)
e
15. Using a punch, lock the lock nut to prevent rotation.
Attach the transfer cover.
16. Insert an assembly of the annular gear, output flange,

transfer drive gear and bearing into the case.
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22> 2%245
17. Install snap ring on output flange bearing.
18. Coat petroleum jelly on the spacer and attach it to the

transaxle case.
19. Install two taper roller bearings to transfer idler gear.

_ Torque converter side
H Groove
20. Place the transfer idler gear (assembled in the preceding

section) into the case, and-then insert the idler shaft from
the outer side of the case and screw it in.
21. In this condition, attach the special tool to the output shaft
flange, and check to be sure that the output flange turns
easily.
-T1;;z2)6 AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22>
22. Tighten the idler shaft by using special tool.
23. Insert special tool into output flange and measure preload
using a low reading torque wrench.
Adjust preload by tightening or loosening transfer idler
shaft.
Preload: 0.6 Nm (0.6 ft.lbs.)
24. After the preload adjustment is completed, eliminate the

backlash between the idler shaft and the lock plate by
moving the idler shaft in the loosening direction. Attach the
lock plate and tighten the lock plate bolt.
Lock plate bolt : 48-60 Nm (35-43 ft.lbs.)
25. Install bearing retainer, and tighten screws to specified

torque, apply a 5 mm (.2 in.) width of sealant (3M Stud
Locking No. 4176) the top. Sealant should not stick out of
screw head.
Screw: 17-22 Nm (13-15 ft.lbs.)
26. Using a punch, lock the flush head screw to prevent

rotation.
1750186
Identification of thrust bearings, thrust races and thrust washers Unit: mm (in.)
Outer Inner Code Outer Inner Code
Thickness Part No. Thickness Part No.
diameter diameter No. diameter diameter No.
55.7 1.4 48.1 34.4
l 1 MD707271 #4
(2.%8, (2.193) (.055) (1.906) (1.354) -
55.7 1.8 2.4
l 2 MD722552 #5
&6, (2.193) LO71) (1 p5075, $7, (.094)
#l
55.7 2.2 42.6
“3 MD720753’ #6
(2.:6, (2.193) (.087) (1.677) (1.%2,
55.7 2.6 38.7 1.6

*4 MD704936 #7
(2.% (2.193) (.102) (2.?:6, (1.524) (.063)
55.7 1.8 36.4
MD707290 #2 MD72001 0 #8
(2% 12.193) LO71) (2.?47, (1.433) -
48.9 1.0 MD997854
MD728763 #9
(1.925) (1 .z7, (.039) (incl *I) (1% (1.%2) -
27. Apply a coating of petrolatum to thrust bearing #12 and
attach to the planetary carrier.
28. Install the planetary carrier to the case.
29. Assemble the reverse sun gear and the forward sun gear in
the following order:
(1) Attach the seal ring and the snap ring to the reverse sun
gear. When attaching, squeeze the seal ring as shown
in the figure.
(2) Attach the thrust race #9 to the forward sun gear.
(3) Attach the thrust race #IO to the forward sun gear.
(4) Assemble the reverse sun gear and the forward sun
gear.
rust bearing #9
Reverse sun gear
1770066
-
30. Install both of the previously assembled sun gears inside

the planetary carrier.
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22> 211249
31. Install the brake disc and brake plate.
32. Mount the pressure plate which was selected in Step 1.
33. Install the return spring.
34. Apply a coating of petrolatum to the wave spring and attach

it to the center support.
35. Install two new O-rings to hydraulic holes of the center

support.
36. Apply automatic transaxle fluid to the O-rings.
21-250 AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A22>
37. Attach the special tool to the center support, and holding
the tool, slowly insert the center support into the case. m
Caution
Be sure that the wave spring is not out of position. LP
38. Remove the special tool from center support.
39. Fit the snap ring which retains the center support.
At this time, take care to prevent the end of the snap ring
from interfering with the pulse generator mounting hole.
I I
40. Install the anchor rod to transaxle case.
Anchor rod /
41. Assemble a new seal ring (large diameter) and D-ring (small
diameter) to the kickdown servo piston, and install a new
O-ring in the groove around the sleeve; then assemble the
kickdown servo spring, piston and sleeve in the transaxle
case.
42. Press the kickdown servo and sleeve in by using the valve
spring compressor and special tool, and then install the
snap ring.
43. Install kickdown band; attach the ends of band to the ends
of anchor rod and servo piston rod.
44. Putting the kickdown drum into the kickdown band, align
the spline of the drum to that of the reverse sun gear. Place
kickdown band on kickdown drum and tighten kickdown
servo adjusting screw to keep band in position.
45. Apply a coating of petrolatum to thrust bearing #8, and

then attach to the kickdown drum.
46. Apply a coating of petrolatum to thrust race #7, and then

attach to the rear clutch hub.
47. Install clutch hub to sun gear splines.

AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22>
48. Attach thrust bearing #6 onto the hub with petrolatum.
rc;I
v
49. Apply a coating of petrolatum to thrust washer #2 and

thrust bearing #4, and then attach to the rear clutch
assembly.
Thrust bearing #4 1750200
50. Combine the rear clutch assembly and the front clutch
assembly.
Fro& clutch ,75020,
51. Install the clutch assembly.
52. Install the differential assembly.

53. If end play which was measured and recorded at disassem-
bly is not standard value, adjust end play to specification by
selecting thrust race #3.
Standard value : 0.3-1.0 mm (.012-.040 in.)
54. Attach the reused thrust washer #I, or the one selected in
step 51 to the front clutch by using petrolatum.
55. Install special tool to the case.
Thrust race
56. Attach the reused thrust race #3 or the one selected in
step 53 to the oil pump by using petrolatum.
57. Install new oil pump gasket and the oil pump assembly.
AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A22>
58. Install new O-ring in groove of oil pump housing and apply
automatic transmission fluid lightly to outside surface of e
O-ring.
59. Install oil pump assembly by tightening six bolts evenly. i-
When installing this oil pump assembly, be careful that
thrust washer will not drop.
60. Check input shaft end play. Readjust if necessary (see step
53).
Standard value : 0.3-1.0 mm (.012-,040 in.)
Solder 61, Apply solder [length approx. 10 mm (40 in.) and diameter
1.6 mm (.06 in.) to the differential assembly at the locations
“I
-4--J
62. Install the converter housing without gasket.
Caution
Don’t reuse the rubber coated metal gasket which has
been used once.
63. Tighten bolts to specification.

64. Loosen the bolts and remove the converter housing in
order to remove the pieces of solder. If the solder is not
broken, carry out the work in steps (61) to (64) with large
diameter solder.
65. Using a micrometer, measure the thickness of the flattned
solder.
Select the spacer in the following manner according to
measurement.
Add the thickness [0.38 mm (015 in.)] of the rubber coated
metal gasket and the end play LO-O.1 5 mm (O-.006 in.)] of i4
the differential case to the measurement (T). Select a -
spacer which is in the calculated range, In other words,
select a spacer whose thickness is in the range of n+ 0.38
mm (.015 in.)] to [T+ 0.38 mm (.015 in.) - 0.15 mm (.006
2200048 in.)].
AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A22> 21-255
66. Place the spacer selected in Step 65 on the outer race of
Spacer the differential bearing.
1700108
67. Apply silicone grease to hatched area (all gasket surface) of

transaxle case.
68. Install new case gasket on transaxle case.
TFA0020
69. Install converter housing and tighten 14 bolts to 19-23 Nm

(14-16 ft.Ibs.).
70. Install end clutch shaft. Be sure to install the longest spline
toward the front as shown.
71. Fit the thrust washer to the return spring at the end clutch
side.
72. Install the end clutch hub to end clutch.
IThrust \ \ I 73. Attach, by petrolatum, thrust bearing # 13 to the end clutch

hub.
74. Install end clutch assembly.
75. Install a new O-ring in the grooves of the end clutch cover.
Caution
1. Install so that the O-ring is not twisted.
2. Apply a sufficient amount of automatic transmission
fluid to the bearing.
76. Attach the end cover and fasten it with four bolts.
Caution
When installing the end cover, be sure the screw hole is
correctly aligned. If the end cover is turned (after it is
installed) in order to align with the screw hole, the ii
O-ring may be twisted as a result.
d
77. Install O-ring at center of top of valve body assembly (brake
oil pressure passage).
78. Replace the O-ring of the solenoid valve harness grommet
with a new one.
79. Insert the solenoid valve connector into the case.
80. Insert the harness grommet into the case.
81. Inserting the pin of the detent plate into the groove of the
manual valve, install the valve body assembly on the case.
7750157
82. First insert the oil temperature sensor inside the case and
install to the case. Then install to the valve body. Tighten
valve body assembly mounting bolts (IO pieces) to IO- 12
Nm (7.5-8.5 ft.lbs.).
A : 18 mm (709 in.) long
6 : 25 mm (.984 in.) long
C : 40 mm (1.575 in.) long
83. Install oil filter. Tighten four oil filter mounting bolts to 5-7
Nm (4-5 ft.lbs.1.
84. Install five magnets in the five depressions provided on the

oil pan.
Remove metal particles from the magnets and clean the
inside of oil pan then.
85. Install new oil pan gasket and oil pan by tightening 12 bolts
to lo-12 Nm (7.5-8.5 ft.lbs.1
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A22>
86. Install a new D-ring to the kickdown servo switch; then
press into the case and secure it by using a snap ring.
87. Install inhibitor switch and manual lever.

Adjust inhibitor switch. (Refer to P.21-211.)
88. Install the pulse generator A and B.
89. After applying automatic transaxle fluid to outside surface

of oil pump-side cylindrical portion of torque converter,
install torque converter carefully so as not to damage oil
seal lip. Make certain that torque converter is in mesh with
oil pump drive gear.
90. Measure distance between ring gear end and converter
housing end. Torque converter has been properly installed
when measurement is about 12 mm (.47 in.).
91. Using special tools, drive two drive shaft oil seals into
transaxle case.
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33*W4A33> 21-259
TRANSAXLE ASSEMBLY <F4A33-W4A33> N2ll.kB
- REMOVAL AND INSTALLATION <F4A33>

*Removal of Battery *Installation of Air Cleaner, Intercooler and Air Hose
@Draining of Transaxle Fluid A (Refer to GROUP II-Intercooler.)
(Refer to GROUP O-Maintenance Service.) *Supplying of Transaxle Fluid
@Removal of Air Cleaner, Intercooler and Air Hose A (Refer to GROUP O-Maintenance Service.)
(Refer to GROUP II-Intercooler.) *Installation of Battery
20-27 Nm
15-19 ft.lbs.
/ IO-14 N ___.
m
Ibs.
lo-12 Nm
-7-9 fi.lbs.
43-55 Nm
31-40 ft.lbs.
lo-12 Nm
7-9 f?.lbs.
27-34 Nm
20-25 ft.lbs.
30-35 Nm
22-25 ft.lbs.
09A0175
Removal steps
1. Adjusting nut
+4 2. Connection for transaxle control cable
3. Connection for oil cooler hose
4. Transaxle fluid level gauge
e+ 6. Inhibitor switch
connector
connector
10. Connection for speedometer cable NOTE
11. Starter motor (1) Reverse the removal procedures to reinstall.
12. Upper coupling bolt for transaxle (2) I)+ : Refer to “Service Points of Installation”.
assembly and engine assembly (3) m : Non-reusable parts
21-260 AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33.W4A33>
60-80 Nm
43-58 ft.lbs.
60-80 Nm
43-58 ftlbs.
46-53 Nm
33-38 ftlbs.
6113 Nm
30-35
22-25
DO-260 Nm
/_ I/’ 144-188 ftlbs.
25
‘B---17-25 ftlbs.
09140176
13. Under cover

14. Connection for tie rod end
:: 15. Connection for lower arm ball joint
16. Connection for drive shaft (R.H.)
t: 17. Connection for drive shaft (L.H.)
a* 18. Front exhaust pipe
++ 22. Special bolt
23. Transaxle mount bracket NOTE
24. tra-rsaxle assembly lower part coupling (1) Reverse the removal procedures to reinstall.
25. Transaxle assembly (3) m : Non-reusable parts
AUTOMATIC TRANSAXLE - Transaxle Assembly <FQA33*W4A33> 21 kz6’1
REMOVAL AND INSTALLATION <W4A33> N2llA-C
(Refer to GROUP II-Intercooler.)
20-27 Nm
15-19 ft.lbs.
Q lo-14 Nm IO-12 Nm
10 ft.lbs. 7-9 ftlbs.
/
\i 5
43-55 Nm 13 \
27-34 Nm
ft.lbs.
Y
Es.
OQAOl63
Removal steps
1. Adjusting nut
l 4 2. Connection for transaxle control cable
3. Connection for oil cooler hose
4. Transaxle fluid level gauge
l + 6. Connection for inhibitor switch connector
connector
connector
10. Connection for speedometer cable
11. Starter motor irkeverse the removal procedures to reinstall.
12. Upper coupling bolt for transaxle (2) I)+ : Refer to “Service Points of Installation”
assembly and engine assembly (3) m : Non-reusable parts
21-262 AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33*W4A33>
60-80 Nm
43-58 ftlbs.
60-80 Nm
43-58 ft.lbs.
46-53 Nm
33-38 ftlbs.
2- _ Nrn’m-~
__ ad’
1
24-35
17-25
\
16
R
60-72
43-52 ft.jbs. I m
36-46 Nm
26-33 ftlbs.
70-80 Nm
51-58 ftlbs.
OOA0177
13. Under cover 24. FoT;saxle assembly lower part coupling

l *14. Connection
- for tie rod end
15. Connection for lower arm ball joint 25. Transaxle assembly
16. Connection for drive shaft (R.H.)
17. Connection for drive shaft (L.H.)
18. Front exhaust pipe ,.
19. Right member and gusset
20. Transfer assembly NOTE
21. Bell housing cover (1) Reverse the removal procedures to reinstall.
22. Special bolt (2) W : Refer to “Service Points of Removal”.
23. Transaxle mount bracket (3) q : Non-reusable parts
AUTOMATR: TRANSAXLE - Transaxle Assemblv <F4A33*WQA33> 21-263
SERVICE POINTS OF REMOVAL NZlL8AU
14. DISCONNECTION OF TIE ROD END/15 LOWER ARM

BALL JOINT
Refer to P.21-227.
16. REMOVAL OF DRIVE SHAFT (R.H.)/ 17. DRIVE SHAFT
(L.H.) <FWD>
Refer to P.21-227.
16. REMOVAL OF DRIVE SHAFT (R.H.) <AWD>

(1) Use the suitable tool to push out the drive shaft (R.H.]
from the front hub.
I 1 lA0288
(2) Insert a pry bar at the projection part and remove the
drive shaft (R.H.) from the transaxle.
Caution
Do not pull out the drive shaft; doing so will
17. DISCONNECTION OF DRIVE SHAFT (L.H.) <AWD>

(1) Take out the drive shaft by lightly tapping the drive shaft
T.J. case with a plastic hammer.
NOTE
Remove the drive shaft with the hub and knuckle, etc.,
as an assembly.
Caution
1. Removing the drive shaft from the outboard
joint side can cause damage to the inboard joint.
Always use a plastic hammer, etc., to remove
the drive shaft.
2. Tapping on the center bearing can damage it.
Never tap on the bearing.
Refer to GROUP 1 l-Exhaust Pipe and Main Muffler.
Refer to P.21-265.
22. REMOVAL OF SPECIAL BOLT
Refer to P.21-227.

6. INSTALLATION OF INHIBITOR SWITCH
Refer to P.22-211.
2. CONNECTION OF TRANSAXLE CONTROL CABLE
Refer to P.22-211.
AUTOMATIC TRANSAXLE - Transfer 21 L265
TRANSFER .NPlVA-
---. REMOVAL AND INSTALLATION
60-80
43-58
OQAOl70
Removal steps
FFkeverse the removal procedures to reinstall.
1. Front exhaust pipe (2) +e : Refer to “Service Points of Removal”.
:: 2. Transfer assembly (3) q : Non-reusable parts
SERVICE POINTS OF REMOVAL NZlV0A0

Refer to GROUP II-Exhaust Pipe and Main Muffler
After moving the transfer assembly to the left and lowering
the front side, then remove it from the propeller shaft.
Caution
1. Be cautious to avoid damaging the transfer oil seal
lip.
2. The propeller shaft should be suspended so that it
is not sharply bent.
3. Cover the transfer opening with the special tool to
prevent transaxle oil discharge and the entry of
foreign objects.
B99119:
09P0044
TRANSAXLE ASSEMBLY
DISASSEMBLY AND REASSEMBLY <F4A33>
Ii5
24
23
TFA0405’
36. Kickdown servo piston

37. Spring
38. Anchor rod
39. Detent assembly
40. Manual control shaft
41. Parking roller support
42. Oil pan
43. Gasket
44. Oil temperature sensor
45. Oil screen
46. Valve body assembly
1. Torque converter 20. Pressure pla?e 47. Manual control lever
2. Oil pump assembly 21. Brake disc 48. Inhibitor switch
3. Gasket 22. Brake plate 49. End clutch shaft
4. Thrust washer #I 23. Reaction plate 50. Bearing retainer
5. Front clutch assembly 24. Reverse sun gear 51. Thrust bearing #I 1
6. Thrust race #3 25. Thrust bearing #8 52. End clutch hub
7. Thrust bearing #4 26.
- - Thrust
- race #9 53. Thrust washer
8. Thrust washer #2 27. l-or-ward sun gear 54. End clutch assembly
9. Rear clutch assembly 28. Planetary carrier assembly 55. O-ring
10. Thrust bearing #5 29. Thrust bearing #I 0 56. End clutch cover
11. Rear clutch hub 30. Output flange 57. Pulse generator
12. Thrust race #6 31. Oil level gauge 58: Lock bolt
13. Thrust bearing #7 32. Oil filler tube 59. Idler shaft
14. Kickdown band 33. Snap ring 60. Idler gear
15. Kickdown drum 34. Kickdown servo switch 61. Spacer
16. Snap ring 35. Snap ring 62. Gasket
72
58
qo T9 I
46
8 \ 43
42
63. Idler gear cover 70. Output bearing retainer

64. Differential bearing retainer 71. Transfer shaft
65. Outer race 72. Transaxle case
66. Differential front bearing cap
67. Differential assembly
68. Gasket TFAO410
69. Differential cover
DISASSEMBLY AND REASSEMBLY <W4A33>
TFA0409

37. Spring
38. Anchor rod
39. Detent assembly
40. Manual control shaft
41. Parking roller support
42. Oil pan
43. Gasket
17. Center support 44. Oil temperature sensor
18. Wave spring 45. Oil screen
19. Return spring 46. Valve body assembly
1. Torque converter 20. Pressure plate 47. Manual control lever
2. Oil pump assembly 21. Brake disc 48. Inhibitor switch
3. Gasket 22. Brake plate 49. End clutch shaft
4. Thrust washer #I 23. Reaction plate 50. Bearing retainer
5. Front clutch assembly 24. Reverse sun gear 51. Thrust bearing #I 1
6. Thrust race #3 25. Thrust bearing #8 52. End clutch hub
7. Thrust bearing #4 26. Thrust race #9 53. Thrust washer
8. Thrust washer #2 27. Forward sun gear 54. End clutch assembly
9. Rear clutch assembly 28. Planetary carrier assembly 55. O-ring
10. Thrust bearing #5 29. Thrust bearing #IO 56. End clutch cover
11. Rear clutch hub 30. Output flange 57. Pulse generator
12. Thrust race #6 31. Oil level gauge 58. Lock bolt
13. Thrust bearing #7 32. Oil filler tube 59. Idler shaft
14. Kickdown band 33. Snap ring 60. Idler gear
15. Kickdown drum 34. Kickdown servo switch 61. Spacer
16. Snap ring 35. Snap ring 62. Gasket
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33.W4A33> 21-269
,1 --
,56
I
31
32
36
37
-a 58 -
,.
// 46
69
66
e
I
42
TFA0411
-. 63. idler gear cover 69. Differential cover 75. Center bearing retainer
64. Differential bearing retainer 70. Output bearing retainer 76. Front output shaft
65. Spacer 71. Center differential assembly 77. Rear output shaft
66. Differential front bearing cap 72. Center bearing retainer 78. Transaxle case
67. Differential assembly 73. Stopper ring
68. Gasket 74. Viscous coupling unit
-m-m AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33*W4A33>
DISASSEMBLY N21WM
Caution %T
1. Since the automatic transaxle is made of particularly ~_,
high precision parts, be very careful when handling
them during disassembly and reassembly so that they
are not scratched.
2. Spread a rubber mat on the workbench and keep it
clean.
3. Do not use cotton gloves or cloth rags during dis-
assembly. If they are needed, use nylon cloth or paper
towels.
4. Clean all disassembled parts. Clean metal parts with
normal cleanser and completely dry with air.
5. Clean the clutch disc, resin thrust plate and rubber
parts with ATF (automatic transmission fluid) and do
not get any dirt on them.
6. If the transaxle itself is damaged, disassemble and
clean the cooler system also.
1. Remove the torque converter.

2. Mount the dial gauge on the transaxle case and measure
the end play of the input shaft.
3. Remove the brackets.
4. Remove the oil level gauge and oil level gauge guide. 1:
5. Remove the pulse generator A and B.
6. First remove the manual control lever and then remove the
inhibitor switch.
7. Remove the speedometer driven gear assembly.
8. Remove the oil pan, magnet and gasket.
9. Remove the oil screen.
10. Remove the valve body mounting bolts (10).

11. Remove the oil temperature sensor holder and then
remove the oil temperature sensor harness from the
clamp.
A0110
12. Press the clips of the solenoid valve harness grommet,

push the grommet inside the case and remove the valve
body assembly.
13. Pull out the oil temperature sensor.
14. Remove the parking roller support.

15. Remove the set screw in the manual control shaft and pull
out the manual control shaft assembly.
16. Remove the detent assembly. As?
17. Remove the differential cover and gasket.
18. Remove the differential front bearing cap.
19. Remove the differential bearing retainer, spacer and outer

race (FWD only).
20. Remove the differential assembly.

AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33.W4A33> 21-213
21. Remove the end clutch cover mounting bolts and then
remove the end clutch cover.
22. Remove the end clutch assembly.
23. Remove the thrust plate.
24. Remove the end clutch hub.

25. Remove the thrust bearing.
NOTE
Sometimes it sticks to the end clutch hub.
26. Pull out the end clutch shaft.

27. Remove the idler gear cover mounting bolts and then
j remove the idler gear cover and gasket.
*
.G-/
28. Release the bolt stopper and then remove the bolt.
29. Using the special tool, pull out the idler shaft and then
remove the idler gear and bearing inner race.
30. Remove the spacer.
31. Remove the oil pump bolts.

AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A33*W4A33> 21-275
32. Using the special tool, remove the oil pump.
rhru
33. Remove the thrust washer and thrust race.
34. Holding the input shaft, remove the front clutch assembly
and rear clutch assembly together.
36. Remove the rear clutch hub.

NOTE
Sometimes the thrust race sticks to the clutch hub.
38. Remove the kickdown drum.
39. Remove the kickdown band.
40. Remove the snap ring and then remove the kickdown servo
switch.
41. Using the special tool, push in the kickdown servo piston
and remove the snap ring.
-
AUlDlpTATTc TRANSAXLE - Transaxle Assembly <F4A33.W4A33> 21-277

42. Remove the kickdown servo piston.
43. Remove the anchor rod.
44. Remove the plug and then remove the air exhaust plug.
46. Using the special tool, remove the center support.

47. Remove the reverse sun gear and forward sun gear.
48. Remove the planetary carrier assembly.
49. Remove the waved spring, return spring, reaction plate,

brake disc and brake plate.
50. Remove the screw and then remove the rear bearing
retainer.
51. Remove the snap ring and then remove the output flange
assembly.
52. Remove the output bearing retainer mounting bolts and
then remove the output bearing retainer and outer race.
I TFA0149
53. Remove the transfer shaft <FWD only>.
/ / TFAOlSOl
54. Insert a rod 8mm (.31 in.) in diameter and 200mm (7.87 in.)
in length from the hole shown in the figure and punch out
the rear output shaft <AWD only>.
55. Using the special tool, remove the center differential

<AWD only>.
TFA0152 .j
56. Put a bolt (M6) into the center bearing retainer and, holding
that bolt, remove the center bearing retainer and outer race
<AWD only>.
57. Remove the center bearing retainer stopper bolt <AWD
only>.
A.
58. First remove the stopper ring and then put a bearing puller
or similar tool in the viscous coupling groove and pull out
the viscous coupling <AWD only>.
59. Remove the front bearing retainer mounting bolt (MIO).

Then, screw a bolt (Ml 2) into the threaded hole of the front
bearing retainer and, holding that bolt, remove the front
bearing retainer and outer race <AWD only>. 6
TFA0156 1
60. Remove the front output shaft <AWD only>.
61. Using a sliding hammer or similar tool, remove the outer

race.
62. Remove the oil seals.
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33*W4A33> 21281
REASSEMBLY NZlLFAO
Caution
1. Do not reuse the gasket, O-ring, oil seal, etc. When
assembling, replace with new parts. (Note: The oil
level gauge rubber need not be replaced.)
2. Do NOT use any grease except petrolatum.
3. First apply ATF to the friction elements, the rotating
parts and sliding parts and then assemble.
Soak new clutch disc and brake disc in ATF for over 2
hours before using.
4. Do not use a sealing agent or adhesive agent on the
gaskets.
5. When replacing the bushing, replace the assembly that
includes the bushing.
6. Do not use cotton gloves or rags (cloth) when assemb-
ling. If required, use nylon cloth or paper towels.
7. Also replace the oil in the cooler.
1. Using the special tool, press-fit the drive shaft oil seal.
Special tools
Front M D998325
FWD
Rear M D998325
Front M D998803
AWD
Rear MD998325
TFA0159
Caution
iWD (Front side) Align with the case positioning boss and assemble so
the oil seal flange pieces are on top wheh put in the car.
MD998803
3. Using the special tool, press-fit the outer race in the

transaxle case.
4. Install the front output shaft assembly <AWD only>.
\ TFAOi57
AWD 5. Position the solder approx. 10 mm (.40 in.) long by 1.6 mm

(.06 in.) in diameter in the front bearing retainer in the
position shown in the figure and then install the outer race
cAWD only>.
A
TFAOl63
1 6. Install the front bearing retainer and tighten the bolt with
the specified torque <AWD only>.
Front bearing retainer mounting bolts:
43-55 Nm (32-39 ft.lbs.)
7. Loosen the bolts and remove the front bearing retainer
<AWD only>.
8. Remove the outer race from the front bearing retainer and
remove the solder. If the solder does not break, perform
bearing retainer
the work in steps 5-8 with large diameter solder. Measure
the thickness of the crushed solder with a micrometer and
TFA0156
select a spacer with the correct thickness so the pre-load
reaches the standard value <AWD only>.
9. Install the spacer selected in the previous step and the
outer race in the front bearing retainer <AWD only>.
10. First install the front bearing retainer and apply sealant to
the bolts and then tighten with the specified torque <AWD h
only>. k
Specified sealant: 3M Stud Locking Part No.4170 or
equivalent
Front bearing retainer mounting bolts:
43-55 Nm (32-39 ftlbs.)
AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A33*W4A33> 21-283
11. Using a bearing puller, support the viscous coupling and
insert in the case. Then, install the stopper ring <AWD
only>.
12. Using the special tool, install the outer race in the center
bearing retainer. <AWD only>.
6990936
TFA0164
13. Install the center bearing retainer stopper bolt <AWD

only>.
Center bearing retainer stopper bolt:
4-6 Nm (3-4 ft.lbs.)
14. Install the center bearing retainer so the projection of the

stopper bolt fits in the groove of the center bearing retainer
<AWD only>.
15. Install the special tool in the center differential and install
the center differential in the transaxle case <AWD only>.
21-284 AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A33*W4A33>
16. Install the transfer shaft <FWD only>.
/ / TFAOlSO
17. Position solder approx. 10 mm. (.40 in,) in length and 1.6
mm (06 in.) in diameter in the output bearing retainer as
shown in the figure and then install the outer race.
TFA0167
18. Install the output bearing retainer and tighten the bolts with
the specified torque.
Output bearing retainer mounting bolts:
20-27 N m ( 1 5 - 1 9 ft.lbs.) ,+
19. Loosen the bolts and remove the output bearing retainer. --
Outph bearing retainer TFAOl49
20. Remove the outer race from the output bearing retainer
and remove the solder. If the solder does not break,
perform the work in steps 17-20 with large diameter
solder. Measure the thickness of the crushed solder with a
micrometer and select a spacer with the correct thickness
so that the pre-load reaches the standard value.
Standard value: 0.075-0.135 mm (.0030--0053 in.)
21. Install the spacer and the outer race selected in the
previous step in the output bearing retainer.
22. Install a new O-ring in the outer circumference of the

output bearing retainer.
23. Apply ATF to the O-ring, install the output bearing retainer
and tighten the bolts with the specified torque.
Output bearing retainer mounting bolts:
20-27 N m ( 1 5 - 1 9 ft.lbs.) -
-
24. Insert the output flange in the case and install the snap ring
on the outside circumference of the bearing.
25. Use new bolts when installing the bearing retainer.

Bearing retainer mounting bolts:
17-22 Nm (13-14 ft.lbs.1
26. Caulk the bolt heads.
r..
Thrust 27. Apply petrolatum to thrust bearing #IO and stick in the
earing #IO planetary carrier.
TFAOlM
28. Install the planetary carrier.

21-286 AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A33.W4A33>
Identification of thrust bearings, thrust races and washers Unit: mm (in.)
Outer Inner Code Outer Inner Thickness Part No.

diameter Thickness Part No. diameter cE,c
diameter No. diameter
55.7 1.4 48.1 34.4 MD707271 #4

*I (1.354) -
(2?6, (2.193) (055) (1.906)
55.7 1.8 42.6 MD720753 #5

(2Y6, (.071) ‘2 (I .677) (l?YO) -
(2.193)
#I
55.7 38.7 1.6 MD704936 #6
(2’706, (2.193) c.z7r *3 (25;3, (I ,524) (.063)
55.7 2.6 36.4 MD72001 0 #7

*4 (25:5, (I ,433) -
(27% (2.193) (.I021
MD731 2 1 2 #2 MD735062 #8
(2T0, (Z, (.El, $7, (12130, -
48.9 1.0 M D997854 0.8 MD735063 #9
(I ,925) (1?6) (.039) (incl. *I) (I%, (I?21 LO31 1
48.9 1.2 MD997847 36.4 MD720010 #IO
(I ,925) (I?& (.047) (incl. *I) (25:5, (1.433) -
48.9 1.4 MD997848 MD724206 #I 1
(1.925) (13:6, (055) (incl. “2) (2Y9, (I?31 -
48.9 yy7qg
(I ,925) ( 13:6, (.I%, I .
I 48.9
(I ,925)
48.9
(1%6,
2.0
(.079)
2.2
MD997851
(incl. “3)
MD997852
I I L
(I ,925) (1?6, (.087) (incl. *4)

48.9 2.4 y.~~~7~~“,3
(I .925) ( 1?6, (.094) I .
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33*W4A33> 21 b287
29. Assemble the forward sun gear, thrust race #9, thrust
bearing #8 and reverse sun gear.
:\ bearing #8 1770066
30. Install the two sun gears assembled in the previous step in
the planetary carrier.
31. Install the reaction plate, brake disc and brake plate.
Caution
When using a new brake disc, first soak it for over 2
hours in ATF.
32. Install the pressure plate used during disassembly and then
install the return spring.
Caution
Be sure to install the return spring in the correct
direction.
33. Apply a coating of petrolatum to the waved spring and

attach it to the center support.
21-288 AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A33.W4A33>
34. Install the special tool on the center support, install new
O-rings (2 locations) pressing them into the transaxle case.
a
Caution
1. Apply ATF to the O-ring and align the oil hole. L
2. Install so the waved spring is aligned.
35. Install the snap ring.
36. Measure the end play of the low reverse brake with a
thickness gauge and select and adjust the pressure plate so
it is within the standard value.
Standard value: l.O- 1.2 mm (.039-.047 in.) v
37. Install the air exhaust plug and then install the plug.
Air exhaust plug: 30-35 Nm (22-25 ft.lbs.)
38. Install the anchor rod.
‘I
39. Install the kickdown servo spring, piston and sleeve.
Caution
The kickdown servo piston seal ring end should not
coincide with the oil supply ports (arrows in figure on
left).
40. Using the special tool, press in the kickdown servo piston
and sleeve and install the snap ring.
41. Install the kickdown band.

Caution
Install so the direction indicated by the arrow is to the
front.
42. Install thrust bearing #4 and thrust washer #2 in the rear

clutch.
43. Assemble the rear clutch and front clutch.
TWO270
7-hrust bearing #5 44. Install thrust bearing #5 in the rear clutch hub.
WA0271
45. Install the rear clutch hub in the rear clutch.
46. Install thrust race #6 on the end of the rear clutch hub.
Thrust
race #6
TFA0273
47. Install thrust bearing #7 in the kickdown drum.
48. Assemble the clutch assembly and kickdown drum.

49. Install the clutch assembly and kickdown drum at the same
time in the transaxle case.
Thrust race #3 I 50. Stick thrust race #3 and thrust washer #l to the rear end
of the oil pump with petrolatum.
51. Using the special tool, install a new oil pump gasket and oil
pump assembly.
Oil pump assembly mounting bolts:
19-23 Nm (14-16 klbs.)
52. Measure the input shaft end play and, if it is outside the
standard value, replace thrust race #3 and thrust washer
#I and adjust so it reaches the standard value.
53. Install the spacer, idler gear and bearing and then insert the
idler shaft.
Caution
Install so the identification groove on the end of the
idler gear is toward the back side.
54. Tighten the idler shaft lock bolt to the specified torque and
use a new lock plate so it doesn’t turn.
Idler shaft lock bolt: 31-44 Nm (23-31 ft.lbs.)
Idler gear 55. Install the idler gear cover and a new gasket.
cover
Idler gear cover mounting bolts:
lo-12 Nm (7.5-6.5 ftlbs.)
I TFAOl2r
56. Insert the end clutch shaft from the long direction of the
spline.
57. Insert the thrust washer in the end clutch return spring.
58. Install the end clutch hub in the end clutch assembly.
17502X J
AUTOMATIC TRANSAXLE - Transaxle Assembly <F4A33*W4A33i 21-293
59. Stick thrust bearing #I 1 to the end clutch hub with
petrolatum.
60. Install the end clutch assembly.
61. Install a new O-ring in the end clutch cover.
62. Install the end clutch cover and tighten the bolts with the
specified torque.
End clutch cover mounting bolts:
IO-12 Nm (7.5-6.5 ftlbs.)
63. Install the differential assembly.

21-294 AUTOMATIC TRANSAXLE - Transaxle Assemblv <F4A33*W4A33>
64. Position solder approximately 10 mm (39 in.) in length and

1.6 mm (06 in.) in diameter in the bearing outer race in the
position shown in the figure <AWD only>.
65. Position solder approximately 10 mm (39 in.) in length and

1.6 mm (.06 in.) in diameter in the differential rear bearing
retainer in the position shown in the figure and then install
the outer race <FWD only>.
66. Install the differential rear bearing retainer and tighten the
bolts with the specified torque.
Differential rear bearing retainer mounting bolts:
30-40 Nm (22-28 ft.lbs.1
67. Loosen the bolts, remove the differential rear bearing
retainer and then remove the solder. If the solder does not
crush, perform the work in steps 64-68 with large
diameter solder.
‘/ TFAOl16
68. Measure the thickness of the crushed solder with a

micrometer and then select and install a spacer so the end
play and pre-load reach the standard value.
Standard value
Front differential case end play:
0.045-0.165 mm (.0017-.0064 in.) <AWD only>
Front differential case preload:
0.075-0.135 mm (.0030-.0053 in.) <FWD only>
69. Install a new O-ring in the differential rear bearing retainer,

apply ATF and then install in the transaxle case. Tighten the
bolts with the specified torque.
Differential rear bearing retainer mounting bolts:
30-40 Nm (22-28 ft.lbs.)
TFA0590
-
AUTOMATIC TRANSAXLE - Transaxle Assembly < F4A33*w4A33> 2 I-295
70. Install the front bearing cap and tighten the bolts with the
specified torque.
Differential front bearing cap mounting bolts:
60-80 N m (44-57 ft.lbs.)
71. Install the differential cover and a new gasket.

Differential cover mounting bolts:
IO-12 Nm (7.5-8.5 ft.lbs.)
72. Install the detent assembly.
73. First install a new O-ring in the manual control shaft

assembly and apply ATF. Then insert it in the transmission
case.
74. Align the manual control shaft groove and set screw hole
and install the set screw.
Manual control shaft set screw:
8-10 Nm (6-7 ft.lbs.)
75. Install the parking roller support.

Parking roller support mounting bolts:
20-27 Nm (15-19 ft.lbs.1
76. Put the oil temperature sensor in the case.
77. Install an O-ring in the O-ring groove on top of the valve

body assembly.
78. Replace the solenoid valve harness grommet O-ring with a

new O-ring.
79. Pass the solenoid valve connector through from the inside
of the transaxle case hole.
80. Insert the solenoid valve harness grommet in the case hole. ,**%
4
81. Temporarily install the valve body while inserting the detent
plate pin in the manual valve groove. Then install the oil
temperature sensor and holder and tighten the bolts with
the specified torque.
A bolt = 18 mm (.71 in.)
B bolt = 25 mm (.98 in.)
C bolt = 40 mm (1.57 in.)
Valve body assembly mounting bolts:
lo-12 Nm (7.5-8.5 fklbs.)
Caution
Fix the solenoid valve and oil temperature sensor
harness securely in the position shown.
82. Install the oil filter.
Oil filter mounting bolts: 5-7 Nm (4-5 ft.lbs.1
83. Install the magnet in the oil pan and then install the oil pan.
Oil pan mounting bolts: IO-12 Nm (7.5-8.5 ft.lbs.)
84. Install the inhibitor switch and manual control lever.

Inhibitor switch mounting bolts:
Inhibitor switch lo-12 Nm (7.5-8.5 ft.lbs.)
Manual control lever mounting bolts:
17-21 Nm (13-15 ftlbs.)
85. Install the speedometer gear assembly.
Speedometer gear locking plate mounting bolts:
4-6 Nm (3-4 ftlbs.)
Pulse generator mounting bolts:
lo-12 Nm (7.5-8.5 ft.lbs.)
86. Install pulse generator A and B.

Caution
Install pulse generator A (with transparent tube) to the
end clutch side and pulse generator B (with black tube)
to the output gear side.
87. Install the oil filler tube and insert the level gauge.
Oil filler tube mounting bolts:
20-27 Nm (15-19 ft.lbs.)
88. Install the brackets.
Transaxle mounting bracket bolts:
60-80 N m (44-57 ftlbs.)
89. Adjust the kickdown servo.
90. Install the kickdown servo switch and fix the snap ring.
91. Insert the center shaft and hit it with a plastic hammer or
similar instrument to install it securely <AWD only>.
NOTE
Apply ATF to the oil seal lip and do not scratch it.
92. Apply ATF to the oil pump drive hub, install the torque
converter and push it in securely so dimension A shown in
the figure reaches the standard value.
Standard value: Approximately 16.3 mm (.642 in.)
CAUTIONS DURING COMPONENT DISASSEM-

BLY AND REASSEMBLY
General cautions when cleaning
1. Clean each part, blow out oil passages and oil holes, etc.
with air and check that nothing is clogged.
2. For cleaning fluid, use the designated ATF (automatic
transmission fluid) or kerosene.
3. When drying parts with air, be careful not to get ATF or
kerosene on your face.
Cautions when handling parts
1. After washing the parts, arrange them in order so inspec-
tion, repairs and assembly can be performed properly.
2. When disassembling the valve body, store each valve,
making a group of the various springs.
3. Soak the new brake and clutch discs used for replacement
in ATF for more than 2 hours before assembly.
General cautions during reassembly
1. Be sure to apply ATF to seal rings, clutch disc, clutch plate
and rotating parts and sliding parts and then install.
2. Replace all gaskets and O-ring with new ones and do not
reuse the old ones.
3. Use petrolatum to hold the parts in their specified places.
AUTOMATIC TRANSAXLE - Oil Pump 21-299
OIL PUMP NZlLGAK
11 Nm
8 ft.lbs.
TFAO?AS
Disassembly steps
l * 1. O-ring
l 2. Reaction shaft support
I)+ 3. Steel ball
We+ 4. Drivegear
+I) l 5. Driven gear
NOTE 6. Snap ring (F4A22)
(I) Reverse the disassembly procedures to reassemble. 7. Oil seal (F4A22)
(2) +I) : Refer to ;Servjce Pojnts of Disassembly”. 8. Seal ring
I:/ &B : Refer to Serwce Points of Reassembly . l * 9. Oil seal
: Non-reusable parts 10. Oil pump housing

4. REMOVAL OF DRIVE GEAR/5. DRIVEN GEAR
Make reassembly alignment marks on the drive and driven
gears.

9. INSTALLATION Of OIL SEAL
Pump housing
Using the special tool, install the oil seal in the pump
housing.
TFAO203
21-300 AUTOMATIC TRANSAXLE - Oil Pump
5. MEASUREMENT SIDE CLEARANCE OF DRIVEN GEAR/
4. DRIVE GEAR
Measure the side clearance of the oil pump gear and *A
replace the gear or oil pump assembly if it exceeds the -’
standard value.
Standard value: 0.03-0.05 mm (.OOl-.002 in.)
3. LOCATION OF STEEL BALL

Install a steel ball in the position shown in the figure.
I 2. INSTALLATION OF REACTION SHAFT SUPPORT

(1) Assemble the reaction shaft support and pump housing
and tighten the bolts by hand.
(2) Insert the special tool (guide pin MD998336) in the oil ;?
pump mounting bolt hole and tighten the outside ‘II.
circumference using the special tool (band MD9983351
to position the support and housing.
(3) Tighten the five bolts to the specified torque.
(4) Make sure that the oil pump gear turns freely.
TFA0201 1
Install a new O-ring in the groove of the pump housing and
apply petrolatum to the O-ring.
AUTOMATIC TRANSAXLE - Transfer Shaft <F4A33> 21-301
TRANSFER SHAFT <F4A33> N21LVAA
TFAO322
Disassembly steps
4+ W 1. Taper roller bearing
4+ l 2. Taper roller bearing
3. Transfer shaft
NOTE
(2) *e : Refer to “Service Points of Disassembly”.

1.12. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the bearings on both ends of
the transfer shaft.
Front side SERVICE POINTS OF REASSEMBLY

MD99881 2
1.12. INSTALLATION OF TAPER ROLLER BEARINGS
Using the special tool, install the bearings on the transfer
MD998822
shaft.
21-302 AUTOMATIC TRANSAXLE - Front Clutch Assembly
FRONT CLUTCH ASSEMBLY NZlUAF

No. of clutch discs and plates
1 Model ( Cldy;c,h ( Cl;,:“h
1 F4A22 ) 3 1 3
TFA0422
6 - Disassembly steps
l 4 1. Snap ring
l * 2. Clutch reaction plate
l 4 3. Clutch disc
4. Clutch plate
~~ 5. Clutch pressure plate
+eW 6. Snap ring
7. Return spring
8. Front clutch piston
9. D-ring
10. D-ring
11. Front clutch retainer
NOTE
(3) : Refer to “Service Points of Reassembly”.
(4) : Non-reusable parts
TFAQ423
AUTOMATIC TRANSAXLE - Front Clutch Assemblv 21-303
(1) Compress the return spring with the special tool.
(2) Remove the snap ring.
1750266
MD998337
\ 6. INSTALLATION OF SNAP RING
(2) Install the snap ring.
1750264
5. INSTALLATION OF CLUTCH PRESSURE PLATE/3.

CLUTCH DISC/P. CLUTCH REACTION PLATE
(1) Assemble the clutch pressure plate, clutch plate and
clutch reaction plate, arranging them by the missing
tooth [See figure @I.
NOTE
This is so the automatic transmission fluid escapes
easily and there is good cooling of the plate and disc.
/ TFA0498 i
Clutch reactior (2) Assembly the plates so the beveled side is as shown in
the figure.
(3) Assemble so the thickest plate (clutch reaction plate) is
on the snap ring side.
TFA0424
1. SELECTION OF SNAP RING

Check clearance between the snap ring and clutch reaction
plate. To check the clearance, hold entire circumference of
the clutch reaction plate down with 50 N (11 Ibs.) force. If
clearance is out of standard value, select a snap ring to
obtain the standard value.
Standard value:
0.7-0.9 m m (.028-.035 in;) <F4A22>
0.8-1.0 mm (.032-.039 in.) <F4A33.W4A33>
269
21-304 AUTOMATIC TRANSAXLE - Rear Clutch Assembly <F4A22>
REAR CLUTCH ASSEMBLY <F4A22> NZlLHBG
DISASSEMBLY REASSEMBLY
17 16 11 9 8 7
\
Disassembly steps
1. Seal ring
l + 2. Input shaft 15 141312 10
3. O-ring
4. Snap ring 1750215
5. Thrust race
6. Seal ring
++ 7. Snap ring
l + 8. Clutch reaction plate
9. Clutch disc
I)+ 10. Clutch plate
l + 11. Clutch pressure plate
++ I)+ 12. Wave spring
13. Return spring NOTE
14. Rear clutch piston (1) Reverse the disassembly procedures to reassemble.
15. Rear clutch retainer (2) +I) : Refer to “Service Points of Disassembly”.
16. D-ring (3) e+ : Refer to “Service Points of Reassembly”.
17. D-ring (4) m : Non-reusable parts
AUTOMATIC TRANSAXLE - Rear Clutch Assemblv <F4A22> 21-305
12. REMOVAL OF WAVE SPRING
(2) Using a screwdriver, remove the wave spring.

MD998337 12. INSTALLATION OF WAVE SPRING
(1) Compress return spring with the special tool.
(2) Install the wave spring.
11. INSTALLATION OF CLUTCH PRESSURE PLATE/IO.

CLUTCH PLATE/8. CLUTCH REACTION PLATE
(1) Install the clutch pressure plate, clutch plates and clutch
reaction plate with their missing tooth portions (@ in
the illustration) in alignment.
NOTE
This design is to facilitate escape of automatic transmis-
sion fluid and improve the cooling efficiency of the
plates and disc.
(2) Install the clutch reaction plate with its shear droop
Shear droop Clutch disc directed as shown in the illustration.
TFA0501

\ 1750275
21-306 AUTOMATIC TRANSAXLE - Rear Clutch Assembly <F4A22>
1. INSTALLATION OF INPUT SHAFT
Install the input shaft with its oil groove aligned with the oil cF
hole in the rear clutch retainer.
AUTOMATIC TRANSAXLE - Rear Clutch Assemblv <FQA33*W4A33> 21-307
REAR CLUTCH ASSEMBLY <F4A33*W4A33>

,A- DISASSEMBLY AND REASSEMBLY
--.
TFAO 606
9 .TFA0265
Disassembly steps
** *4 12. Snap ring
1. Seal ring 13. Return spring
l 2. Input shaft 14. Rear clutch piston
3. O-ring 15. D-ring
4. Snap ring 16. D-ring
5. Thrust race 17. Rear clutch retainer
6. Seal ring
l + 7. Snap ring NOTE
I)+ 8. Clutch reaction plate (1) Reverse the disassembly procedures to reassemble.
9. Clutch disc (2) +e : Refer to “Service Points of Disassembly”.
l + 10. Clutch plate (3) l + : Refer to “Service Points of Reassembly”.
11. Wave spring (4) 0 : Non-reusable parts
21-308 AUTOMATIC TRANSAXLE - Rear Clutch Assembly <F4A33.W4A33>
S E R V I C E P O I N T S O F DISASSEM.BLY
(1) Using the special tool, compress the returns spring.
(2) Using the snap ring pliers, remove the snap ring.

(1) Using the special tool, compress the return spring.
(2) Using the snap ring pliers, install the snap ring.
10. INSTALLATION OF CLUTCH PLATE/*. CLUTCH REAC-
/ @
TION PLATE
Assemble the clutch plate and reaction plate, arranging
them by the missing tooth [See figure @I.
(
NOTE
This is so the automatic transmission fluid escapes easily
and there is good cooling of the plate and disc.

TFAO240
2. INSTALLATION OF INPUT SHAFT

Align the input shaft oil groove and rear clutch retainer
matching mark and assemble.
AUTOMATIC TRANSAXLE - End Clutch Assembly 21-309
END CLUTCH ASSEMBLY NZIIJWD
.- DISASSEMBLY AND REASSEMBLY

No. of clutch discs and plates
F4A22 3 3
9
TFA0607
Disassembly steps
1. Seal ring
l * 2. Snap ring
3. Clutch reaction plate
4. Clutch disc
5. Clutch plate
l + 6. Snap ring
7. Washer TFA0608
8. Return spring 5
9. End clutch piston NOTE
10. Oil seal (1) Reverse the disassembly procedures to reassemble.
11. D-ring (2) l e : Refer to “Service Points of Disassembly”.
12. End clutch retainer (3) ++ : Refer to “Service Points of Reassembly”.
13. Oil seal (4) q : Non-reusable parts

Using the special tool, install the snap ring.
Caution
Check that the snap ring is seated firmly in the groove.
AUTOMATIC TRANSAXLE - End Clutch Assembly
First install the snap ring and then check if the gap between
the snap ring and clutch reaction plate reaches the standard ,“i
value. When measuring the gap, press the circumference
of the clutch reaction plate firmly with a force of 50 Nm (11
Ibs.). If the gap is outside the standard value, select a snap
ring and adjust until it reaches the standard value.
Standard value:
0.4-0.65 mm (.016-.026 in.) <F4A22>
0.6-0.85 mm (.024-.033 in.) <F4A33*W4A33>
TFA0268
AUTOMATIC TRANSAXLE - Planetary Gear <F4A22> 21-311
PLANETARY GEAR <F4A22> NZlLKAJ
-. DISASSEMBLY AND REASSEMBLY
I ,. / .
ep4”
8
9 TFAOS22
Disassembly steps
I. Bolt
2. Lock plate
3. One-way clutch outer race
4. End plate
35-45 Nm 1)4 5. One-way clutch
26-32 ft.lbs. 6. End plate
7. Pinion shaft
8. Front thrust washer
9. Spacer bushing
NOTE 10. Short pinion
(I) Reverse the disassembly procedures to reass$mble. Il. Roller
(2) *I) : Refer to ::Servjce Points of Disassembly,
Ii/ + : Refer to Service Points of Reassembly . +e l + 12. Thrust bearing
b : Non-reusable parts 13. Planet carrier

12. REMOVAL OF THRUST BEARING
(1) Remove the only one short pinion. Use care not to drop
and lose the 17 rollers in the short pinion. Do not
remove the other short pinions.
(2) Remove the thrust bearing.

21-312 AUTOMATIC TRANSAXLE - Planetary Gear <F4A22>
12. INSTALLATlON OF THRUST BEARING %
(1) Install a thrust bearing on the carrier. Make sure that it c,i
fits correctly in the spot faced portion of the carrier.
(2) Apply Vaseline unsparingly to the inside surface of the

short pinion and attach the 17 rollers on the surface.
(3) Line up the holes of the rear thrust washer and front
thrust washer “A” with the shaft hole of the carrier.
(4) Install the short pinion, spacer bushing and front thrust
washer and align the holes. Use care not to allow the r?
rollers to get out of position. .*-d’
(5) Insert the pinion shaft. Make sure that the flattened end
of pinion shaft is correctly fitted in the hole of the rear
thrust plate when the pinion shafts is inserted.
5. INSTALLATION OF ONE-WAY CLUTCH

Push the one-way clutch into the outer race. Make sure
that arrow on the outside circumference of cage is directed
upward as shown in the illustration when the one-way
clutch is pushed in.
J-+
-il
AUTOMATIC TRANSAXLE - Planetary Gear <F4A33.W4A33> 21-313
PLANETARY GEAR <F4A33=W4A33>
TFA0491
Disassembly steps
1. Thrust bearing
4*+4 2. Rivet
e+ 3. Waved washer
NOTF 4.
- -One-way
. . clutch outer race
(1) Reverse the disassembly procedures to reassemble. 5. tnd plate
(2) +e : Refer to “Service Points of Disassembly”. ~~ 6. One-way clutch
(3) l : Refer to “Service Points of Reassembly”. 7. End plate
(4) m : Non-reusable parts 8. Planet carrier

2. REMOVAL OF RIVET
(1) Move the stopper plate so it does not hit the rivet head.
NOTE
The catch of the stopper plate should not catch in the
one-way clutch outer race groove.
(2) Use a pin punch or similar tool and drive out the rivet.
21-314 AUTOMATIC TRANSAXLE - Planetary Gear <F4A33.W4A33>
6. INSTALLATION OF ONE-WAY CLUTCH *b*
Press in the one-way clutch so the gauge part of the cJ
one-way clutch is in the direction shown by the arrow in the
figure.
3. INSTALLATION OF WAVED WASHER

Install so the concave (indented) part of the waved washer
is on the outer race side.
TFM0506
2. INSTALLATION OF RIVET
Using a punch, caulk the rivet by pressing.
NOTE r
Use a punch with a tip with a 60” angle.
Caulk the rivet surely with a load of 1 l,OOO-13,000 N es
(2,425-2,866 Ibs.).
‘I
AUTOMATIC TRANSAXLE - %t:i kk?& set <F4A22> 21-315
ANNULUS GEAR AND TRANSFER DRIVE GEAR SET <F4A22> NzlwE
WASSEMBLY AND REASSEMBLY
Disassembly steps
l + 1. Snap ring
+eM 2. Bearing
W l 3. Transfer drive gear
+er)+ 4. Bearing
5. Snap ring
6. Outbut flange
7. Annulus gear
NOTE
(2) +e : Refer to “Service Points of Disassembly”. 170178
(3) H : Refer to “Service Points of Reassembly”.
/ SERVICE POINTS OF DISASSEMBLY

Using the special tool, remove the bearing from the output
M D998348 flange.
170113
3. REMOVAL OF TRANSFER DRIVE GEAR

Using the special tool, remove the transfer drive gear from
the output flange.
MD998348
170114
Using the special tool, remove the bearing from the output
flange.
MD998348
170115
Annulus Gear and
21-316 AUTOMATIC TRANSAXLE - Transfer Drive Gear Set <F4A22>

4. INSTALLATION OF BEARING L:
Using the special tool, install the bearing on the output *h-
flange.
MD998813
TFAO502
3. INSTALLATION OF TRANSFER DRIVE GEAR

Using the special tool, install the transfer drive gear in
proper direction. The direction can be identified by the
groove provided in one of the pinion side surfaces.
Caution
Replace the output flange and transfer drive gear as a
set.
TFA0503
2. INSTALLATION OF BEARING
Using the special tool, install the bearing on the output
flange.
MD99881 2 @%
MD998824
TFA0384

Select a snap ring, which should be the thickest one that
can be installed in groove.
170120
Annulus Gear and
AUTOMATIC TRANSAXLE - Transfer Drive Gear Set 44A33.W4A33> 21-317
ANNULUS GEAR AND TRANSFER DRIVE GEAR SET <F4A33*W4A33>
Disassembly steps
l * 1. Snap ring
2. Stopperplate
4eI)+ 3. Bearing
l W 4. Bearing
We+ 5. Transferdr ive gear
6. Snar, rina
7. Outbut frange
8. Annulus gear
NOTE
(3) ++ : Refer to “Service Points of Reassembly”.

3.14. REMOVAL OF BEARINGW5. TRANSFER DRIVE
GEAR
(1) Using the special tool, remove the transfer drive gear
and bearings (2) as a set from the output flange.
Caution
Install the special tool securely between the output
flange and bearings.
) Using the special tool, remove the bearings on both

ends of the transfer drive gear.
TFA0225
21-318 AUTOMATIC TRANSAXLE - EEtC EELCar set <F4A33.W4A33>

5. INSTALLATION OF TRANSFER DRIVE GEAW4.13. A,
BEARINGS L-1
(1) Using the special tool, press-fit the bearings on both
ends of the transfer drive gear.
TFA0226
r (2) Using the special tool, install the transfer drive gear on
the output flange.

Measure the snap ring groove, select and install a spacer so
the end play reaches the standard value.
AUTOMATIC TRANSAXLE - Differential
DIFFERENTIAL
- DISASSEMBLY AND REASSEMBLY NZlLNAF
1
130-140 Nm
34-101 ft.lbs.
k
TWO263
Disassembly steps
l 1. Bolt
2. Differential drive gear
4e e4 3. Ball bearing <F4A22-W4A33>
+e l a 4. Taper roller bearing <F4A33>
*ee+ 5. Lock pin
l + 6. Pinion shaft
l + 7. Pinion
l 8. Washer
e+ 9. Sidegear $?everse the disassembly procedures to reassemble.
l + 10. Spacer (2) +e : Refer to “Service Points of Disassembly”.
Il. Differential case (3) l + : Refer to “Service Points of Reassembly”.

Using the special tool, remove the ball bearing.
21-320 AUTOMATIC TRANSAXLE - Differential
Using the special tool, remove the taper roller bearing. L+

Using a pin punch, drive out the lock pin.
NOTE
Sometimes the lock pin is removed with a light punch.
(F4A33)
TFA0231

10. INSTALLATION OF SPACER/S. SIDE GEAR/8.
WASHERI7. PINION/G. PINION SHAFT
(1) First assemble the spacer on the rear of the side gear &a
and then assemble the gear in the differential case. .--
(2) Assemble the washer on the rear of the pinion, and
position in the designated place by rotating the two side
gears at the same time so they mesh.

Pinion, shaft Pinion gear
/
(4) Measure the backlash between the side gear and

pinion.
Standard value: 0.025-0.150 mm (.OOl-.0059 in.)
(5) If backlash is outside the standard value, select a
spacer, disassemble the gear again, reassemble and
adjust.
Ld
NOTE
Adjust so backlash in both side gears is the same.
AUTOMATIC TRANSAXLE - Differential 21-321
Align the lock pin hole in the pinion shaft and the lock pin
hole in the case and then install the lock pins.
Caution
1. Do not reuse lock pins (F4A22wW4A33).
2. Make the lock pin lower than the surface of the
differential case flange.
3. Press-fitting load is over 5,000 N (1,100 Ibs.)
(F4A22sW4A33).

Using the special tool, press-fit the taper roller bearing in
the differential case.

. MD99881 2 Using the special tool, press-fit the ball bearing in the
differential case.
MD998822
TFY0040
1. INSTALLATION OF BOLTS
Apply ATF to the differential drive gear bolts, install and
tighten with specified torque in the order shown in the
figure.
Differential drive gear bolt:
130-140 Nm (94-101 ft.lbs.)
I 166630
r
21-322 AUTOMATIC TRANSAXLE - speed ometer Gear AssemMylKickdown Servo
SPEEDOMETER GEAR ASSEMBLY NzlLaA6
DISASSEMBLY AND REASSEMBLY +.
201076
Disassembly steps
1. O-ring
NOTE l + 2. Spring pin
(1) Reverse the disassembly procedures to reassemble. H 3. Speedometer driven gear
(2) l : Refer to “Service Points of Reassembly”. 4. Oil seal
(3) q : Non-reusable parts 5. Sleeve

3. INSTALLATION OF SPEEDOMETER DRIVEN GEAR
Apply gear oil sparingly to the speedometer driven gear
shaft and insert the shaft. “c,
L_,
Install the spring pin in such a way that its slit does not face
the gear shaft.
Slit
201079
KICKDOWN SERVO NZlLPAE
6
Disassembly steps
I. O-ring
2. Kickdown servo
3. D-ring
4. Seal rina
5. Locknuj
6. Kickdown servo rod
1750299
NOTE
AUTOMATIC TRANSAXLE - Low-Reverse Brake 21-323
LOW-REVERSE BRAKE N21LSAA
c-
TFA0386
1. Low-reverse brake piston

2. D-ring
3. D-ring
4. Center support
!yTEeverse the disassembly procedures to reassemble.

21-324 AUTOMATIC TRANSAXLE - Valve Body
VALVE BODY NZlLOAK
DISASSEMBLY AND REASSEMBLY Viewed from A
-0 - -
TFA0523
Disassembly steps
1. Manual valve
l + 2. Pressure control solenoid valve
l + 3. Damper clutch control solenoid v<ralve
<F4A22>
l + 4. Shift control solenoid valve “A”
l + 5. Shift control solenoid valve “B”
6. Clamp
7. Valve stopper
8. N-D control sleeve
9. N-D control valve
l + 10. Lower valve body sub assembly
11. Lower separating plate
12. Nut
13. Jet
l + 14. Relief spring
l + 15. Steel ball
H 16. Oil filter
W 17. Upper valve body sub assembly
WI 18. Steel ball
H 19. Teflon ball
l 4 20. N-D elate
NOTE 21. Block
(1) Reverse the disassembly procedures to reassemble. 22. Upper separating plate
(2) l 4 : Refer to “Service Points of Reassembly”. 23. Intermediate plate
AUTOMATIC TRANSAXLE - Valve Bodv
26 46
38
24
I
Viewed from B
I
40
TFA0518
24. Fornt end cover 38. 2-314-3 shift spring

25. Pressure control spring 39. 2-3/4-3 shift valve
26. Pressure control valve 40. Rear end cover
27. Torque converter control spring 41. Shift control plug B
28. Torque converter control valve l + 42. Stopper plate
29. Adjusting screw 43. Shift control valve
30. Regulator spring 44. l-2 shift spring
31. Regulator valve 45. l-2 shift valve
32. Shift controlspring 46. Upper valve body
++ 33. Stopper plate
34. Shift control plug
35. Rear clutch exhaust valve A NOTE
36. Rear clutch exhaust valve B (1) Reverse the disassembly procedures to reassemble.
37. Rear clutch exhaust spring (2) I)4 : Refer to “Service Points of Reassembly”.
21-326 AUTOMATIC TRANSAXLE - Valve Body
TFAOS22
47. Pin 58. N-R control spring

48. Stopper 59. Adjusting screw
49. End clutch plug 60. Reducing spring
50. End clutch spring 61. Reducing valve
51. End clutch valve 62. Lower valve body
52. End cover
53. Plug <F4A33.W4A33>
54. Damper clutch control sleeve <F4A22>
55. Damper clutch control valve <F4A22> NOTE
56. Damper clutch control spring <F4A22> (1) Reverse the disassembly procedures to reassemble.
57. N-R control valve (2) l 4 : Refer to “Service Points of Reassembly”.
AUTOMATIC TRANSAXLE - Valve Body 21-327
42./33. LOCATION OF STOPPER PLATES/SO. N-D PLATE/
19. TEFLON BALL/18. STEEL BALL
Install the stopper plates, N-D plate, teflon ball and steel
ball in the upper valve body in the positions shown in the
figure.
17. INSTALLATION OF UPPER VALVE BODY SUB ASSEM-

BLY
Install the special tool, then, after securing the upper
separating plate and the intermediate plate by the eight
installation bolts, remove the special tool.
18. INSTALLATION OF OIL FILTER/IS. S T E E L BALL/

14. RELIEF SPRING
Install, to the intermediate plate, the oil filter, the two steel
balls, and the spring.
MD998226 10. INSTALLATION OF LOWER VALVE BODY SUB ASSEM-

BLY
(1) Install the special tool to the intermediate plate.
(2) Install the separating plate.

21-328 AUTOMATIC TRANSAXLE - Valve Bodv
(3) After securing the lower valve body by the installation
bolt, remove the special tool.
Sk
5./4./3./2. INSTALLATION OF SOLENOID VALVE ASSEM-

BLY
Install each solenoid valve in the position shown in the
figure.
Solenoid valve Wiring color I

Shift control solenoid valve “A”
Shift control solenoid valve “B” Yellow
XSV-A SkV-B rj,,SV (FJA22)
TFAM80 Damper clutch control solenoid valve Red
Pressure control solenoid valve Blue
AUTOMATIC TRANSAXLE - Center Differential <W4A33> 21-329
CENTER DIFFERENTIAL <W4A33> NZlLWM
TEA0261
Disassembly steps 11. Side gear (rear)

12. Clip
l * 1. Transfer driven gear l * 13. Spacer
+e l 2. Taper roller bearing 14. Center differential case
l * :z i. poy;r roller beanng
5: Center differential flange
l + 6. Spacer
7. Side gear (front) FEeverse the disassembly procedures to reassemble.
8. Pinion shaft (2) +e : Refer to ZServjce Pojnts of Disassembly’:‘.
9. Pinion 1:: 4 : Refer to Serwce Points of Reassembly
10. Washer &I : Non-reusable parts

1. REMOVAL OF TRANSFER DRIVEN GEAR
Remove the transfer driven gear.
NOTE
If it is hard to remove, use the special tool to remove it.
21-330 AUTOMATIC TRANSAXLE - Center Differential <W4A33>
Using the special tool, remove the taper roller bearing from /ic
the transfer driven gear. ‘;-

Using the special tool, remove the taper roller bearing from
the center differential flange.

13.16. SELECTION OF SPACERS
(1) Install the spacer, side gear (rear), pinion, washer and
pinion shaft in the center differential case. rs,
(2) While pressing the pinion shaft, select the thickest -m ,-’
spacer to gently rotate the pinion.
(3) Install the side gear (front), spacer and center differen-
tial flange and tighten the bolts with the specified
torque.
Center differential drive gear bolt:
70-80 Nm (51-57 ft.lbs.)
(4) Using the front output shaft, rotate the side gear front
and select the thickest spacer to gently rotate the side
gear front.
4. INSTALLATION OF BOLT
First apply sealant to the end [5 mm (2 in.)] of the bolt
threads and then tighten to the specified torque in the order
Center differential drive gear bolt:
70-80 Nm (51-57 ft.lbs.) *
Specified adhesive: MOPAR Part No.4318031 or +’
MOPAR Part No.4318032 or
equivalent
AUTOMATIC TRANSAXLE - Center Differential <W4A33> 21-331
Using the special tool, install the taper roller bearing on the
center differential flange.

Using the special tool, install the taper roller bearing on the
transfer driven gear.
21-332 AUTOMATIC TRANSAXLE - Front Output Shaft <W4A33>
FRONT OUTPUT SHAFT <W4A33> NZlLXAA

2
I I
Disassembly steps
*I) l 1. Taper roller bearing
+e l 4 2. Taper roller bearing
3. Front output shaft
NOTE
(3) l 4 : Refer to “Service Points of Reassembly”.

1./2. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the taper roller bearings on
both ends of the front output shaft.

2./l. INSTALLATION OF TAPER ROLLER BEARINGS
Using the special tool, press-fit the taper roller bearings on
both ends of the front output shaft.
MD998822
AUTOMATIC TRANSAXLE - Transfer Assembly <W4A33> 21-333
TRANSFER ASSEMBLY NElVE-
35-42 Nm
26-30 ft.lbs.
TFAO601
Disassembly steps
1. Cover
2. Cover gasket
3. Extension housing assembly
4. Oil guide
l I 5. Transfer case sub assembly
l 6. Spacer $?everse the disassembly procedures to reassemble.
7. O-ring (2) l 4 : Refer to “Service Points of Reassembly”.
l + 8. Transfer case adapter sub assembly (3) m : Non-reusable parts
21-334 AUTOMATIC TRANSAXLE - Transfer Assemblv <W4A33>
SERVICE POINTS OF REASSEMBLY WmnAE
8. INSTALLATION OF TRANSFER CASE ADAPTER SUB +=G
ASSEMBLY -
Using a brush, apply a thin even coat of machine blue or
minium to both tooth surfaces of the driven bevel gear.
2210050
5. INSTALLATION OF TRANSFER CASE SUB ASSEMBLY

(1) Tighten the transfer case adapter sub assembly on the
transfer case sub assembly to the specified torque.
\
-;--.
-
TifAO315
(2) Using the special tool, turn the drive bevel gear shaft
MB991144
one turn each in the direction of normal and reverse
rotation.
Caution
Do not rotate the drive bevel gear shaft more than
one turn as it cause a blurred tooth contact pattern.
(3) Make sure that the contact pattern of the driven bevel
gear teeth is correct.
NOTE
See Tooth Contact Adjustment Procedure on next page
for the standard tooth contact pattern.
4
-am--
AUTOMATIC TRANSAXLE - Transfer Assembly <W4A33> 21-335
(4) Check to see if the backlash between the drive and
driven bevel gears is up to specification.
Standard value
Bevel gear set backlash:
0.08-0.13 mm (.0031-.005 in.)
TOOTH CONTACT ADJUSTMENT PROCEDURE

1. Standard tooth contact pattern
A: Small end
B: Drive side tooth surface
(The side receiving force in forward motion)
C: Big end
D: Coast side tooth surface
(The side receiving force in reverse motion)
2210061

high
Possible cause:
The driven bevel gear is too close to the drive bevel gear.
2210092
Remedy:
Use a thicker spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is further away
from the drive bevel gear.
2210093
3. INSTALLATlON OF EXTENSION HOUSING ASSEMBLY

Apply sealant to the flange surface of the adapter and install
the housing.
Specified sealant: Mitsubishi genuine Part No.997740
or equivalent
Caution
Squeeze out the sealant from t h e t u b e u n i f o r m l y
without excess or discontinuities.
21-336 AUTOMATIC TRANSAXLE - Transfer Assembly <W4A33>
low
A-k
Possible cause:
The driven bevel gear is further away from the drive bevel ~
gear than necessary.
2210094
Remedy:
Use a thinner spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is closer to the
drive bevel gear.
2210095
NOTE
(1) If correct tooth contact cannot be obtained by replace-
Spacer for ment of spacer for adjusting driven bevel gear mount,
adiustina drive change the spacers for adjustment of drive bevel gear
bekel gear mount Spacer for preload and drive bevel gear mount adjustment to those 4
\ of appropriate thickness as described below and adjust -.’
bevel gear preloac
the tooth contact again.
l If the driven bevel gear height is still too small when
the thinnest spacer for driven bevel gear mount
adjustment [0.13 mm (.005 in.)] is used;
Change the spacer for drive bevel gear mount
Spacer for adjustment to the next thicker one and change the
adjusting spacer for drive bevel gear preload adjustment to
/ driven bevel the next thinner one.
gear mount
l If the driven bevel gear height is still too large when
the thickest spacer for driven bevel gear mount
Spacer for adjustment [0.52 mm (021 in.)] is used;
, adjusting
driven bevel Change the spacer for drive bevel gear mount
gear preload adjustment to the next thinner one and change the
spacer for drive bevel gear preload adjustment to
the next thicker one.
Repeat above steps until standard tooth contact
pattern is obtained.
(2) If the tooth contact pattern cannot be brought close to
the standard pattern by the adjustment described
above, replace the drive bevel gear and driven bevel
gear as a set and adjust the tooth contact again.
2210129
AUTOMATIC TRANSAXLE - Extension Housing Assembly <W4A33> 211337
EXTENSION HOUSING ASSEMBLY NZlVGAA
Disassembly steps
l + 1. Air breather
>- 2. Dust seal guard R3
l * 3. Oil seal
4. Extension housing
NOTE
MD99881 2 SERVICE POINTS OF REASSEMBLY

MD998822 3. INSTALLATION OF OIL SEAL
TFA0319

Apply sealant to the air breather port and fit the air breather
in position.
lent
2010043
21-338 AUTOMATIC TRANSAXLE - Transfer Case Adapter Sub Assembly 4W4A33>
TRANSFER CASE ADAPTER SUB ASSEMBLY <W4A33> N21VlAA
Disassembly steps
4**+ 1. Locknut
4* 2. Driven bevel gear
I)4 3. Taper roller bearing
*4 ;. ;z;;r 140-150 Nm
102-115 ft.lbs.
6: Outer race
7. Outer race
8. Transfer case adapter
4e W 9. Taper roller bearing
NOTE
(2) 4e : Refer to ::Service Points of Disassembly:‘.
[j &@ j Refer to Service Points of Reassembly
Non-reusable parts TEA0 604

1. REMOVAL OF LOCK NUT
(1) Unstake the lock nut.
(2) Remove the driven bevel gear’s lock nut by using the
II MB991013
special tool.
TFAO289
AUTOMATIC TRANSAXLE - Transfer Case Adapter Sub Assembly <W4A33> 21-339
2. REMOVAL OF DRIVEN BEVEL GEAR ASSEMBLY
Using a press, remove the driven bevel gear assembly.
TFAO290


MD99881 2 9. INSTALLATION OF TAPER ROLLER BEARING
Using the collar, install the taper roller bearing.
MD99881 3
I MD99881 4
M D998825
4. SPACER SELECTION
(1) First install the spacers used up to this time, and then
assemble the transfer case adapter sub-assembly.
(2) Using the special tool, measure the rotating drive
torque of the driven bevel gear and select spacer(s) so it
reaches within the standard value.
Standard value: 1.0-l .7 Nm (0.72-I .23 ft.lbs.)
21-340 AUTOMATIC TRANSAXLE - Transfer Case Adapter Sub Assembly <W4A33>
Fb MD99881 2
MD99881 4
Using the special tool, install the taper roller bearing.
MD998822
TFAO311
1. INSTALLATION OF LOCK NUT

(1) Tighten the driven bevel gear’s lock nut at the specified
torque by using the special tool.
(2) Stake the lock nut at two places for locking.

AUTOMATIC TRANSAXLE - Transfer Case Sub Assembly <W4A33> 21-341
TRANSFER CASE SUB ASSEMBLY NZlVJAA
TFA0603
I
35-42 irn
i
26-30 ftlbs.
Disassembly steps
1. Transfer cover
2. O-ring
r)+ 3. Spacer
4. Outer race
5. Drive bevel gear shaft
6. Outer race
** 7. Spacer
I)+ 8. Oil seal NOTE
9. Transfer case (1) Reverse the disassembly procedures to reassemble.
10. Drive bevel gear (2) +e : Refer to “Service Points of Disassembly”.
~~ e+ 11. Taper roller bearing (3) ~~ : Refer to “Service Points of Reassembly”.
~~ e+ 12. Taper roller bearing (4) m : Non-reusable parts
21-342 AUTOMATIC TRANSAXLE - Transfer Case Sub Assembly <W4A33>

11./12. REMOVAL OF TAPER ROLLER BEARINGS ri
Using the special tool, remove the taper roller bearing. -I

12./l 1. INSTALLATION OF TAPER ROLLER BEARINGS
MD99891 2 Using the special tool, install the taper roller bearing.
\ r,
MD998827.
MD99881 2
MD99881 8
TFA0302

AUTOMATIC TRANSAXLE - Transfer Case Sub Assembly <W4A33> 21-343
7.13. SPACER(S) SELECTION
(1) First install the spacers used up to this time and then
assemble the transfer case subassembly.
(2) Using the special tool, measure the rotating drive
torque of the drive bevel gear and select spacer(s) so it
reaches the standard value.
Standard value: 1.7-2.5 Nm (1.23-1.81 ft.lbs.)
Caution
Select spacers of nearly same thickness on both
sides.
NOTES
22-l
-.
WHEELS
AND TIRES
CONTENTS NZZAA-
SERVICE ADJUSTMENT PROCEDURES.. ..... 4 TROUBLESHOOTING ...................................... 3

Tire Inflation Pressure Check ...................... 4 Bald Spots
Tire Wear Check .......................................... 4 Cracked Treads
Wheel Runout Check ................................... 4 Feathered Edge
Rapid Wear at Center
SPECIFICATIONS ............................................. 2
Rapid Wear at Shoulders
Scalloped Wear
Wear on One Side
7 Torque Specifications ................................... 2
WHEEL AND TIRE .......................................... 5
5 22-2 WHEELS AND TIRES - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS N22CA- @N
Vehicles with ~eDhL”~~HWCthEngine Vehicles with Vehicles with

Items 1.8L Engine 2.0L DOHC Engine 2.0L DOHC Engine
<Non-Turbo> <Turbo>-FWD <Turbo>-AWD
Wheel
Tire size PI 85/70R14 P205155Rl6 89H P205/55R16 89V P205/55R 16 89V
P205155R16 89V 205/55R 16 88V 205/55R16 88V
205/55R16 88V
Wheel type Steel type Steel/Aluminium type Aluminium type Aluminium type
Wheel size 14 x 5’/2JJ 16 x 6JJ 16 x 6JJ 16 x 6JJ

Amount of wheel offset
mm (in.) 46 (1.8) 46 (1.8) 46 (1.8) 46 (1.8)
Tire inflation pressure
kPa (psi)
Front 200 (29) 200 (29) 200 (29) 220 (32)
Rear 180 (26) 180 (26) 180 (26) 200 (29)
Spare wheel
Tire size T125/70D15 T125/70D15 T125/90D16
T125/80D16*
Wheel size 4T x 15 4T x 15 4T x 16
4T x 16”
Amount of wheel offset
mm (in.) 46 (1.8) 46 (1.8) 46 (1.8)
Tire inflation pressure
kPa (psi) 420 (60) 420 (60) 420 (60)
NOTE
*: <ABS>
I 1 terns Specifications
Limit
Wheel runout
Radial mm (in.) 2.0 (.08)
Lateral mm (in.) 2.0 i.08)
Tread depth of tire mm (in.) 1.6 l.06)
TORQUE SPECIFICATIONS Nz2cG-
Items Nm ftlbs.
Hub nuts 120-140 87-101
WHEELS AND TIRES - Troubleshooting 22-3
TROUBLESHOOTING N22EA-
Rapid wear Under-inflation or Adjust the tire pressure
at shoulders lack of rotation
Rapid wear Over-inflation or

at center lack of rotation
Cracked Under-inflation
treads
Wear on Excessive Inspect the camber

one side camber
Feathered
Adjust the imbalanced wheels
Rotate the tires Inspect the front sus-

pension alignment
22-4 WHEELS AND TIRES - Service Adjustment Procedures

TIRE INFLATION PRESSURE CHECK N2ZFOAC
Check the inflation pressure of the tires. If it is not within the

standard value, make the necessary adjustment.
TIRE WEAR CHECK N2zFsAB

Measure the tread depth of tires.
Limit: 1.6 mm (.06 in,)
Wear indicator If the remaining tread depth is less than the limit, replace the
tire.
NOTE
When the tread depth of tires is reduced to 1.6 mm (.06 in.) or
less, wear indicators will appear.
53r510
WHEEL RUNOUT CHECK NZ2FCA5
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with a
dial indicator.
Limit:
Radial 2.0 mm (.08 in.)
Lateral 2.0 mm (.08 in.)
If wheel runout exceeds the limit, replace the wheel.
/ Lateral 11Y602
WHEELS AND TIRES - Wheel and Tire 22-5
WHEEL AND TIRE NUGA-
Steel type
120-140 Nm
Aluminium type 87-101 ftlbs. liA0334
120-140 Nm
87-101 ft.lbs.
lA0267
o-140 Nm
1
87-101 ft.lbs.
/ llA0336
7
Removal steps
1. Wheel cover <Vehicles with wheel cover>
2. Center cover <Vehicles with center cover>
I)+ 3. Hub nuts
4. Center cap <Vehicles with center cap>
5. Spring
6. Ornament
7. Balance weight NOTE
8. Tire (1) Reverse the removal procedures to reinstall.
9. Wheel (2) l 4 : Refer to “Service Points of Installation”
SERVICE POINT OF INSTALLATION NUGDABa
2. INSTALLATION OF HUB NUTS

On the high speed tire (205/55R16 88V) vehicle, the left and
right tires are respectively specified. Attach the tires as
follows :
Observe the wheel in the P direction as illustrated, and the
direction characters will be found.
Attach the (a Cl ROTATION LEFT SIDE) tire on the left
wheel, and the (ROTATION RIGHT SIDE DD) tire on the
1 lAO265
right wheel.
llAO266
22-6 WHEELS AND TIRES - Wheel and Tire
INSTRUCTIONS FOR ALUMINUM TYPE INSTRUCTIONS FOR COMPACT SPARE
WHEELS UzzGfM TIRE ;c.
1. Aluminum is vulnerable to alkalies. If a vehicle 1. The compact spare tire is designed to. save
washing detergent has been used, or salt from space in the luggage compartment, and its L’
sea water or road chemicals has adhered, wash lighter weight makes it easier to use if a fiat tire
the vehicle as soon as possible. After washing occurs.
the vehicle, apply body or wheel wax to the 2. The following instructions for the compact spare
aluminum type wheels to prevent corrosion. tire should be observed.
2. When cleaning the vehicle with steam, do not (1) Check the inflation pressure after installing
direct steam onto the aluminum type wheels. the spare, and adjust to the specified pres-
When tightening nuts for aluminum type sure.
wheels, particularly observe the following: (2) Avoid driving through automatic car washes
(1) Clean the hub surface of aluminum type and over obstacles that could possibly dam-
wheels. age the vehicle’s undercarriage. Because
(2) After finger-tightening wheel nuts, tighten the tire is smaller than the original tire, car
them to specifications. ground clearance is slightly reduced.
(3) Do not use an impact wrench or push the (3) The compact spare tire should not be used
wrench by foot to tighten the wheel nuts. on any other wheels, nor should standard
(4) Do not apply oil to the threaded portions. tires, snow tires, wheel covers or trim rings
be used with the compact spare wheel. If
INSTRUCTIONS FOR TIRE CHAINS AND such use is attempted, damage to these
SNOW TIRES NZZGGAA items or other vehicle components may
occur.
1. Use tire chains only on front wheels. Do not use
tire chains on rear wheels.
2. When using snow tires, use them on all four
wheels for maneuverability and safety.
23-l
BODY
CONTENTS N23Ak-
AERO PARTS .......................................... 74 QUARTER WINDOW GLASS ...................... 61

CENTRAL DOOR LOCKING SYSTEM ........... 70 REAR BUMPER ........................................ 43
DOOR ASSEMBLY .................................... 63 REAR SEAT ............................................ 93
DOOR GLASS AND REGULATOR.. .............. 66 SEAT BELT ............................................. 94
DOOR HANDLE AND LATCH ..................... 69 SERVICE ADJUSTMENT PROCEDURES.. ...... 31
DOOR MIRROR ........................................ 72 Door Adjustment .................................... 32
DOOR MOULDING AND Door Glass Adjustment ............................ 32
DRIP LINE WEATHERSTRIP.. ...................... 72 Door Inside Handle Play Check.. ................ 32
.... DOOR RUNCHANNEL ..... . ......................... 71 Door Outside Handle Play Check ................ 32
DOOR TRIM AND WATERPROOF FILM.. ...... 65 Floor Pan Inspection ............................... 33
ELECTRIC REMOTE CONTROLLED Fuel Filler Door Adjustment.. ..................... 31
MIRROR SWITCH ..................................... 73
Hood Adjustment ................................... 31
FENDER .................................................. 51
Liftgate Adjustment ................................. 31
FLOOR CONSOLE .................................... 84
Water Test ........................................... 33
FRONT BUMPER ...................................... 39
SPECIAL TOOLS ...................................... 5
FRONT SEAT .......................................... 90
SPECIFICATIONS ..................................... 2
FUEL TANK FILLER DOOR.. ....................... 38
General Specifications .............................. 2
GARNISHES ............................................ 47
Lubricants. ............................................ 5
HEADLINING ........................................... 89
Sealants and Adhesives ........................... 5
HOOD .................................................... 34
Service Specifications .............................. 3
INSTRUMENT PANEL ................................ 79
Torque Specifications .............................. 3
LIFTGATE ............................................... 36
SUNROOF ............................................... 77
LIFTGATE WINDOW GLASS ...................... 62
TRIMS .................................................... 85
LOOSE PANEL ......................................... 53
TROUBLESHOOTING ................................ 6
MOULDING ............................................. 48
WINDOW GLASS ..................................... 54
POWER WINDOW .................................... 67
WINDSHIELD ........................................... 58
23-2 BODY - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS N23CA--
Hood
We Rear hinged, front opening type
Door
Construction Front-hinged, sash construction
Regulator system Wire type
Locking system Pin-fork type
Liftgate
We Inner-hinged, with gas damper
Slass installation method
Windshield glass Adhesive type
Quarter window glass Adhesive type
Liftgate window glass Adhesive type
Zlass thickness mm (in.)
Windshield glass 5.3 i.21)
Liftgate window glass 3.5 t.141
Door glass 3.5 t.141
Quarter window glass 3.5 t.141
‘ower window motor
Type Permanent magnet type (Built-in circuit breaker)
Revolutions under no load wm 75 or more
Revolutions under load wm
At 1 Nm t.72 ft.lbs.1 65-95
At 2 Nm (1.45 ft.lbs.1 50-80
Bound current A 34 or less
Direction of rotation Clockwise and counter-clockwise
‘ower window main switch
Type Automatic reset type
Rated load current A
Lock switch 10
Power window switch 10
‘ower window sub switch
Tvw Automatic reset type
Rated load current A 10
‘ower window relay
Maximum contact current A 20
Rated coil current A Max. 0.2
Voltage drop between terminals V 0.2 or less
(At 12 V and the rated load current)
BODY - Specifications 23-3
Door lock control unit
Effective voltage V lo-16
Current consumption (when not in operation) mA 3 or less
Door lock power relay
Range of voltage used V 8-16
Rated load current (at 13.5 VI A 10
Rated coil current A 0.2 or less
Voltage drop between terminals V 0.2 or less
Door lock actuator
Bound current (at 12 VI A 2.5-4.5
Operating voltage range V 9-15
Tripping time (at 12 V)
l second 5-30
Remote control mirror
Remote control mirror motor
Bound current mA 500 or less
Operating voltage range V 9.5-l 5
Door mirror control switch
Rated load mA 50
4utomatic seat belt motor
Type Ferrite magnet motor
Rated voltage V 12
No-load speed wm 140
No-load current A 4
NOTE
l: Tripping time is the time consumed until current reaches 0.5 A after power connection.
SERVICE SPECIFICATIONS N23CB--
Standard value
Door inside handle play mm (in.) 2.5-8.5 (.09-,331
Door outside handle play mm (in.) 2.5-6.5 (.09-.25)
Items Nm ft.lbs.
Hood hinge to hood 9-14 7-10
Hood hinge to body (bolt) 17-26 12-19
Hood hinge to body (nut) 9-14 7-10
Hood latch to body 7-11 5-8
23-4 BODY - SDecifications
Items Nm ft.lbs.
Liftgate hinge to liftgate 9-14 7-10
Liftgate hinge to body I I-16 8-12
Liftgate latch to body 7-l I 5-8
Liftgate striker to liftgate 9-14 7-10
Front bumper absorber mounting nuts 35-55 25-40
Front bumper absorber mounting bolts 17-26 12-19
Rear bumper absorber mounting nuts 35-55 25-39
Rear bumper absorber mounting bolts 17-26 12-19
Fender mounting bolts 4-6 3-4
Splash shield mounting screws 2.0-2.2 1.4-1.6
Splash shield mounting bolts 4-6 3-4
Battery tray to body 9-14 7-10
Hood lock support to body 4-6 3-4
Deck crossmember stay to deck crossmember 4-6 3-4
Door hinge to door 17-26 12-19
Door hinge to body 17-26 12-19
Door striker mounting screws 9-14 7-10
%ont door window regulator to door window glass 2.0-4.0 I .5-3.0
Door latch assembly mounting screws 5-7 4-5
Steering shaft mounting bolt 8-12 6-9
‘rant seat slider rail mounting bolt 35-55 25-40
Yont seat mounting bolt 35-55 25-40
‘rant seat mounting nut 24-36 17-26
‘rant seat slider bracket mounting bolt 35-55 25-40
‘rant seat frame mounting bolt (inner) 10-15 7-l 1
‘rant seat frame mounting bolt (outer) 35-55 25-40
‘rant seat adjuster mounting bolt 9-14 7-10
lear seatback mounting bolt 17-26 12-19
jear seat striker mounting bolt 4-6 3-4
4utomatic seat belt motor mounting bolt 4-6 3-4
jutomatic seat belt guide rail mounting bolt (A), (B) 4-6 3-4
iutomatic seat belt guide rail mounting bolt (Cl 17-26 12-19
detractor assembly (for shoulder belt) mounting bolt (Front) , Vehicles 9-14 7-10
detractor assembly (for shoulder belt) mounting bolt (Rear) for U.S. 35-55 25-40
detractor (for lap belt) mounting bolt (8 x 20 mm bolt) 9-14 7-10
letractor (for lap belt) mounting bolt (7116 in. x 25 mm bolt) 35-55 25-40
;uide ring bracket mounting bolt 9-14 7-10
automatic seat belt buckle mounting bolt 35-55 25-40
Jide bar mounting bolt 35-55 25-40
ront seat belt sash guide mounting bolt Vehicles 35-55 25-40
ront seat belt retractor bracket mounting bolt for Canada 35-55 25-40
Zover plate mounting bolt I 9-14 7-10
‘ear inner seat belt bracket mounting bolt 35-55 25-40
‘ear seat belt anchor plate attaching bolt 35-55 25-40
ear seat belt retractor bracket mounting bolt (Front) 4-6 3-4
ear seat belt retractor bracket mounting bolt (Rear) 35-55 25-40
BODY - Specifications/Special Tools 23-5
LUBRICANTS NZXD-
.^
I Items Specified lubricant I Quantity I
I The sliding portions of the following parts: I I I
Hood latch, hood lock release handle,
hood hinge, liftgate latch, liftgate lock
release handle, liftgate hinge, fuel filler
door, fuel filler door lock release handle, MOPAR Multipurpose Grease As required
door check strap, door hinge, door Part No.2932524 or equivalent
window regulator, door outside handle,
door latch, door inside handle
SEALANTS AND ADHESIVES

Side air dam 3M ATD Part No.6383 or equivalent
Fender to body panel MOPAR Silicone Rubber Sealer Part No.4026070 or equivalent
Fender to splash shield MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto Glass Adhesive and Sealer
Quarterwindow glass to body h-t No.2298825 Or equivalent
Windshield glass and liftgate 3M Super Fast Urethan Part No.8609 or equivalent,
window glass to body 3M Super Fast Urethan Primer Part No.8608 or equivalent
Door inner panel waterproof MOPAR Rope Caulk Sealer 3/l 6 x 80” roll Part No.4026044 or equivalent
film fitting portion
SPECIAL TOOLS
MB990834 Door adjusting Adjustment of door fit
wrench
MB990449 Window moulding Removal of window moulding

remover
BODY - Troubleshooting
TROUBLESHOOTING N23EFd
HOOD, LIFTGATE, GLASS AND DOORS

Hood/ Improper closure Striker and latch not properly aligned Adjust the alignment
Liftgate
Difficult locking and
unlocking
Uneven body Incorrectly installed hood or liftgate Adjust the installation of
clearance hood, deck lid or liftgate
Uneven height Incorrect hood bumper height Adjust the hood bumper,
deck lid bumper or liftgate
bumper height
i/\/indow Water leak through Defective seal Fill sealant
Jlass windshield
Defective body flange Correct
Water leak through Incorrect window glass installation Adjust position
door window glass
Gap at upper window glass Adjust position
Water leak through Defective seal Fill sealant
liftgate window
Defective body flange Correct
Ioors Door window Incorrect window glass installation Adjust position
malfunction
Damaged or faulty regulator Correct or replace
Water leak through Cracked or faulty weatherstrip Replace
door edge
Water leak from Drain hole clogged Remove foreign objects
door center
Inadequate waterproof film contact or damage Correct or replace
Door hard to open Incorrect latch or striker adjustment Adjust
Door does not Incorrect door installation Adjust position
open or close
completely Defective door check strap Correct or replace
Door check strap and hinge required grease Apply grease
Uneven gap Incorrect door installation Adjust position
between body
Wind noise around Weatherstrip not holding firmly Adjust fit of door
door
Improperly installed weatherstrip or setting of Repair or replace
weatherstrip
Improperly closed door Adjust
Improperly fit door Adjust
Improper clearance between door glass and Adjust
door weatherstrip holder
Deformed door Repair or replace
BODY - Troubleshootina 23-7
SUNROOF
Water leaks Dust accumulated in drainage of Keep off dust from inside of drain
housing assembly hose
Clogged drain hose Blow air into drain hose to remove
dust
Broken or dislocated drain hose, Check hose installation and flange
failed or cracked clip contact
Worm roof lid weatherstrip Replace
Excessive roof lid-to-body clearance Adjust
and improperly fitted weatherstrip
Wind noise Loose or deformed deflector Retighten or replace
23-8 BODY - Troubleshooting
HOW TO LOCATE WIND NOISES
( 1) Attach cloth tape to every place which might conceivably be
the source of wind noise, such as panel seams, projections,
moulding seams, glass and body seams, etc.
(2) Then make a road test in order to determine that the places
not covered by tape are not sources of wind noise.
WA0458
(3) Then remove the strips of tape one by one, making a road
test after each is removed, until a wind noise source is
discovered.
(4) When such a place is found, cover it again and continue with
the procedure so as to determine if there are any other noise
sources.
(5) If no others are found, the last remaining tape is the only
source.
(61 Cut the remaining piece of tape into smaller pieces, attach
it again as it was before, and then remove the pieces one
by one in the same way so as to narrow down the source.
15A0455
(7) Check to confirm that wind noise occurs when the last
remaining tape is removed, and that noise does not occur
when it is re-attached.
(8) When the source(s) of the wind noise is finally located,
attach butyl tape, body sealer or similar material to obstruct
this source as much as possible.
WA0455
-
BODY - Troubleshooting 23-9
POWER WINDOW N23EBEE
CIRCUIT DIAGRAM
MAIN SWITCH E-53 JIGl=MJ
J/B ONE-TOUCH WWN CIFXXJIT
I
8
c
-0
t \,:
!Ti
15(A/T) C-67
'1OWT) C-67
5
i
e,,*
'\ A-05X
OWER WINDOW -------___-_
ELAY
1
\I
2
El
128 C-7
468
POWER WINDOW -
MOTOR
E-54
&
:3S-AC-UllO?-NC
OPERATION
l With the ignition switch in the “ON” position, rs;,
press either the “UP” or “DOWN” side of the
power window (main or sub) switch. Electric -*
current will then flow through sub fusible link No.
5 to the power window motor and will operate
the power window motor to open or close the
power window glass.
l Press the DOWN side of the power window main
switch located on the driver’s seat side all the
way. Then the switch will lock and the power
(PABBENGER’B BIDE)
v 1 window motor will continue to operate until the
window glass is fully open.
NOTE
For detailed information on the operation of the
one-touch down (open) mechanism, refer to the
Technical Information Manual.
l To disable both the main and sub switches
except the one located at the driver’s seat, place
the power window lock switch in the “LOCK
(ON)” position. With the switch in this position,
the power window motor will no longer operate
even if the switches are operated.
l The power window motor has a circuit breaker to
prevent damage to the motor due to overcurrent.
Reference: Characteristics of Circuit Breaker
E-51 At normal temperatures [ZO-25OC (68-77”F)I,
bind the motor. Supply current, then the circuit h
breaker will cut off the current in the first 4 to 40 \&’
seconds. The circuit breaker, if left alone, will
reset in less than 60 seconds.
TROUBLESHOOTING HINTS
1. None of the door glasses can be opened or
closed.
0 Check sub fusible link No. 5.
0 Check the power window relays.
l Check the power window main switches.
2. Some, but not all, of the door glasses cannot be
opened or closed.
(I) Do not operate even if both the power
‘S window main and sub switches are pressed.
0 Check power window main switch.
E-05 l Check the power window motor which
I 2 does not operate.
3458
m (2) Do not operate only when either the main or
sub switch is pressed, but do operate when
both are pressed.
0 Check power window switch which does
not operate.
POWER WINDOW 3. The one-touch switch function only does not
MOTOR
E-04 work. A
0 Replace the power window main switch. w
(PASSENGER'S SIDE)
BODY - Troubleshooting 234'1
CENTRAL DOOR LOCKING SYSTEM <Vehicles without Theft-Alarm SySkYII > N23EBFF
..- CIRCUIT DIAGRAM
SUB FU IBLE
LINK 08
g
@L
J/B k 1 c-47 B
'
10A
,-.
L
3 E-64
is4
11 c-51
J/B
L
c-49
4c 12
34
al DOOR LOCK E-49 DOOR LOCK E-09
KX3b-AC-WIOB-Xi:
2342 BODY - Troubleshooting
CENTRAL DOOR LOCKING SYSTEM <Vehicles with Theft-Alarm System>

CIRCUIT DIAGRAM
IGNITI ON IGI
SW1 TCH (ACC) SW
- CH(IG1)
c
3
r' 9
c-54 c3 4------.P 7
IX
0 43
10A 1OA
\/
------.
C-52 1 1
3
-:4 b fl
fiie;yLOCK
c-34x
f!iiGq
THEFT-
ALARM
g$;ROL $j
r - - - - - -
51 z
------. j2 s9 $4m5
!2---w---w---:
?II
- - - -----1(
I
I
I IL-++;
I
I
I
L--------------- _
C-20 5~7f.f5,8m~ii-~,i;----'
I
1
3 E-64
3 E-50
DOOR LOCK E-49 DOOR LOCK E-09

ACTUATOR
%%8°iIDE, m
X95-AC-Ull00-NC
-. l If the inside lock knobs of the doors are placed 1. One of the door lock actuators fails to operate.
in the LOCK (or UNLOCK) position, the switch in l Check the door actuator which fails to
the door lock actuator will be “OFF” (or “ON”), operate.
and the output transistor will be “ON” for 0.5
second according to the timer function in the 2. Cannot be placed in the LOCK or UNLOCK
door lock control unit (or theft-alarm control unit). position by the inside lock knob on either driver’s
As a result, the LOCK side (or UNLOCK side) of or front passenger’s seat side.
the door lock relay will be “ON”, operating the 0 Check the switch in the actuator.
actuators of all of the doors. 0 Check the door lock control unit (or theft-
NOTE alarm control unit).
The door lock actuator contains a PTC thermistor
to prevent damage caused by overheating of the
motor. If the central door lock is frequently used,
the actuator may temporarily fail to operate. If it
returns to normal in a few minutes, it is not
defective.
DOOR LOCK CONTROL UNIT (OR THEFT-ALARM CONTROL UNIT) TERMINAL VOLTAGE (Connector
Connected)
Terminal Terminal
Signal name Condition voltage
No.
1 or 5”’ Door lock relay The moment the inside lock knob is 0.5 vs2
activation signal pressed down (approx. 0.5 sec.)
Normally System voltage
2 or 19”’ (Driver’s seat side) inside When the inside lock knob is placed System voltage
door lock knob signal in the “LOCK” position
When the inside lock knob is placed o v
in the “UNLOCK” position
3 or 4”’ Door lock relay The moment the inside lock knob is 0.5 v2
activation signal pulled up (approx. 0.5 sec.)
Normally System voltage
4 or 20”’ (Passenger’s seat side) When the inside lock knob is placed System voltage
inside door lock knob signal in the “LOCK” position
When the inside lock knob is placed o v
in the “UNLOCK” position
5 or 12*’ Power supply Always System voltage
6 or 7(11)*’ Ground Always o v
NOTE
*I: Vehicles with theft-alarm system.
*2: Because of the internal resistance of the output transistor, the normal terminal voltage is 0.5 V. If it is 0 V, an open or
short circuit in the harness is suspected.
ELECTRIC REMOTE CONTROLLED MIRROR N23EBBD
CIRCUIT DIAGRAM
REMOTE
&;;NT;LLED
1
SWITCH
L \/ \/ -
\I
7 3 ‘9 g i
F
cl, 4t
,C
'E-57
5
IL
;.-- ,,5 E-57 m
F
!3
E-63
#
[z
J/B
E-59 E-03
pJJ%J
I
I I
(RIGHT SIDE) J
L (LEFT SIDE) t
MS-AC-UlSW-NC REMOTE CONTROL MIRROR
l When the remote controlled mirror switch is Neither right nor left mirror operates
operated while the ignition key is in “ACC” or 1) Also cigarette lighter does not operate
“ON” position, current flows through fuse No. 0 Check fuse.
@ remote controlled mirror switch, remote con- 2) Cigarette lighter operates
trolled mirror, remote controlled mirror switch, l Check remote controlled mirror switch.
and ground, causing the mirror to move.
BODY - Troubleshooting 2345
N23EBABa
IUZZER < Vechicles for Canada >
CIRCUIT DIAGRAM
IGNITION 'ITCH(IG1)
J/B 0
10A 1OA
y4 C-52
/
WHEN KEY
IS REMOVED 4,
I
.
6I=
I
I
I
I
I
3?;IWELT
BUZZER
I
I
I
I
I
c
I
I
I
I
I
I
I
I
I
I
I
WITH
I
I R!Ei&-
I ESTEM
I
DIODE
E-52
c-37x \\ (B)
"4
34
El
SEAT BELT
TIMER J/B
\I
"5 c-54
91cu FRONT DOOR SWITCH
(LEFT SIDE)
KX35-AC-UlblB-NC

Key-reminder warning Key-reminder warning
0 Battery voltage is always supplied, through sub The key-reminder warning doesn’t sound.
fusible link No. @, to the key-reminder switch. (1) The seat belt warning function is OK.
0 When the driver’s seat door is opened while the l Check the door switch.
ignition key is still in the key cylinder, the door (2) The seat belt warning also doesn’t function.
switch is switched ON, electricity flows to sub 0 Check the buzzer.
fusible link No. 0, the key-reminder switch, the Seat belt warning
buzzer, the door switch, and ground, and the
buzzer sounds. 1. The seat belt warning doesn’t function.
(1) The seat belt warning light illuminates.
Seat belt warning 0 Check the seat belt switch.
0 Battery voltage is applied, through fuse No. 0, (2) The seat belt warning light also does not
to the seat belt timer when the ignition key is at function (but the key-reminder warning
the “ON” position. functions normally. 1
0 Electricity flows to sub fusible link No. @, the 0 Check the seat belt timer.
key-reminder switch, the seat belt warning light, (3) The seat belt warning light also does not
the seat belt timer, and ground, and the seat belt function (and the key-reminder warning also
warning light illuminates for approx. 6 seconds. does not function).
0 If the driver does not buckle the seat belt, the seat 0 Check the key-reminder switch.
belt switch is switched ON, electricity flows to 2. The buzzer doesn’t stop even though the driver’s
sub fusible link No. @, the key-reminder switch, seat belt has been buckled.
the buzzer, the seat belt switch, the seat belt 0 Check the seat belt switch.
warning timer, and ground, and the buzzer
sounds for approx. 6 seconds. 3. The seat belt warning light doesn’t illuminate (but
0 When the driver buckles the seat belt, the seat the buzzer sounds).
l Check the light bulb.
belt switch is switched OFF and the buzzer stops.
BODY - Troubleshootina 234 7
AUTOMATIC SEAT BELT <Vehicles for U.S. > N23EBGD
CIRCUIT DIAGRAM
IGN ION
SW1 'H (IGl)
b
c 3-BW
1OAb 10A
\,
7 “4 C-52 m
4
14
----- 1
II
I
2L3:I
I
I
f
51 I
COMBINATION I
METER I .---
II
> .,* i
i
I: 6
52 1
D-06 i c
I :
I
13
---- ;
WHEN KE W'HEN KEY
E
l%OVEO &TALLED
13
AUTOMATIC
SEAT BELT
CONTROL UNIT
P
2 m m
St1
ELT
43
cu
!
M6-AC-Ul6lZ-NC
AUTOMATIC SEAT BELT

SUB FUSIBLE LINK Q CONTROL UNIT
I E-41
-------____---__-----~-~--~~~ -----I
1
I
I
I
I
2 E-46 ‘1 I
I I
I I
I I
I
I I
I I
AUTOMATIC SE I I
I BELT MOTOR R I I
(RIGHT SIDE)
I I
!3 I I
I I
I I
I I
I I
I I
ON $ .aOFF II
II
II
II
\/ I 1
j
..I I
II
4
:
‘,“ piaq II
II
_---
c
__3 E!G 5 -------- -- _----------
1
L----------------:
1
1
- - - - - -
I
I
I
iI
-3 At7t
2 I
I
-- 15
_---_---_____---~ __---- J
2. lxs s
L
1:
E-57 1
I
I
++
3 A0 I
1
I
DOOR I
LATCH 7- I
TF;W;H cLo8'
, I I
SIDE) I
AUTOMATIC SEAT BELT 9+3 I Sk3 SIDE) AUTOMATIC SEAT BELT
E-51 I m1 E-07 CONTROL UNIT
CONTROL UNIT ‘p I
12 cr. 1 E-41
E-41 3
5!? ,,7- - - - f IL----CL-,,7
,,
m m
.h7
c-51 - - J/B
LL
, 2 3 4 C-54 “5
6678
5 m
&- R e m a r k
= *The connectqr,indicated,QY
the x SYmbOl i s aPPIicat)le t o
v e h i c l e s w i t h ABS.
BODY - Troubleshootinn 2349
Trouble symptom Cause Check method Remedy
Driver’s and/or Fuse blown or disconnected Check fuse @I Replace or reconnect
front passenger’s the fuse
system does not
function Open harness wire or Check using check charts No. 1, 3 and 5
disconnected connector
Defective switch Check using check chart No. 5
Defective motor Check using check chart No. 3
Defective relay Check using check chart No. 3
Defective control unit - Replace the control unit
Defective driving device - Replace the driving

device assembly
Warning light Fuse blown or disconnected Check fuse @I Replace or reconnect
does not the fuse
lluminate or
flash Open harness wire or Check using check charts No. 1, 2, 4 and 5
Defective switch Check using check charts No. 2, 4 and 5
Warning light bulb blown Check using check chart No. 2

or in poor contact
3uzzer does not Fuse blown or disconnected Check fuse @ Replace or reconnect
sound the fuse
Defective buzzer Refer to Inspection Replace the buzzer

section (P.23-97.)
Open harness wire or Check using check chart No. 2

The slide anchor Defective driving device, Try to move the slide If the slide anchor does
foes not move from or problem in electrical anchor in both directions not move:
he “fasten” range circuit by hand Replace the driving
nto “release” device assembly
ange, or from the
‘ r e l e a s e ” range into If the slide anchor moves:
he “fasten” range Check using check
charts No. 1, 2, 3
and 5
Glide anchor moves Foreign matter in guide rail - Clean or replace the
00 slowly driving device assembly
Slide anchor stops Defective retractor Check retractor operation Replace the retractor
ralfway (remains in locked state) when both pulling out (for shoulder belt)
and retracting belt
Defective driving device Try to move the slide If the slide anchor does
or problem in electrical anchor in both directions not move:
circuit by hand Replace the driving
device assembly
If the slide anchor moves:
Check using check
charts No. 1, 3 and 5
CHECKING CIRCUIT
Index of Check Chart
Chart No. Circuit name Page No.
1 Control unit power supply and ground circuit 23-20
2 Warning light, key reminder switch, buzzer circuit 23-2 1
3 Release switch (driver’s side), buckle switch, outer switch circuit 23-23
4 Door latch switch, fasten switch, release switch (passenger’s side) circuit 23-25
5 Motor power supply and drive circuit 23-28
1. Control Unit Power Supply and Ground Circuit
IGNITION
SWITCH
,\--
AUTOMATIC
SEAT BELT
CONTROL UNIT
Check method T Judgement

Step Cause Remedy
Operation Check object Normal Malfunction
1 Unplug the Harness side System voltage 0 V Open harness wire Repair the harness
connector from terminal voltage or disconnected or plug in the
the control unit of control unit connector between connector correctly
connector junction block and
(I 1 -Ground) control unit
2 Ignition switch: Harness side System voltage 0 V Open harness wire Repair the harness
ON terminal voltage or disconnected or plug in the
of control unit connector between connector correctly
connector junction block and
(1 -Ground) control unit
3 ignition switch: Terminal-to- 00 all Open harness wire Repair the harness
OFF ground continuity between control
of control unit unit and ground
harness side
connector Improper ground Correctly connect
(7-Ground, connection to ground
17-Ground)
1 2. Warning Light, Key Reminder Switch, Buzzer Circuit 1

I I
IGNITION SWITCH <IGl > SUB FUSIBLE LINK @
c-7 ,,7
L7,
,,l
/\
JUNCTION
BLOCK 0 0
IOA IOA
2:
7 y4
.--- 1 WG
114 1
I KEY REMINDER
t I
I
1
SEAT BELT
I WARNING BUZZER
+ installed
I
I
J
11
I
WARNING LIGHT 1
gCTy4;NATION
6 2
3 \I
Nhen k e
L!
>
2 8
emoved
I
I
I
13
_--- -I
10 13 20
I
AUTOMATIC
SEAT BELT w
CONTROL UNIT
Iem
Check method Judgement

Step Cause Remedy
Varning light
1 Unplug the Terminal voltage System voltage 0 V Open harness wire Repair the harnes:
warnrng light of warning light or disconnected or plug in the
connector harness side connector between connector correct1
Ignition switch: connector junction block and
ON (I-Ground) combination meter
2 Connect the Terminal voltage System voltage 0 V Open harness wire Repair the harries:
warnrng light of control unit or disconnected or plug in the
connector. harness side connector between connector correctl!
Unplug the connector combination meter
connector from the (1 -Ground) and control unit
control unit.
Ignition switch: Warning light bulb Replace or
ON blown or in poor correctly install
contact the warning light
ey reminder switch
1 Disconnect the key Terminal voltage System voltage 0 V Open harness wire Repair the harness
reminder switch of key reminder or disconnected or plug in the
connector. switch harness connector between connector correct11
side connector junction block and
t 1 -Ground, key reminder
S-Ground) switch
2 Plug the key Terminal voltage 13-Ground: o v Open harness wire Repair the harness
reminder switch of control unit System voltage or disconnected or plug in the
connector. harness side connector between connector correct11
Unplug the connector key reminder
connector from the (13-Ground, switch and control
control unit 12-Ground) unit
Remove the key
from the ignition 12-Ground: A voltage same as Defective key Check the key
switch. o v or lower than reminder switch reminder switch.
system voltage (Refer to GROUP
84gnition Switch.1
3 Insert the key. Terminal voltage 13-Ground: A voltage same Defective key Check the key
of control unit o v as or lower than reminder switch reminder switch.
harness side system voltage (Refer to GROUP
connector 84gnition Switch.1
(13-Ground,
12-Ground) 12-Ground: o v Open harness wire Repair the harness
System voltage or disconnected or plug in the
connector between connector correctly
key reminder switch
and control unit
lzzer
1 Unplug the buzzer Terminal voltage System voltage 0 V Open harness wire Repair the harness
connector. of harness side or disconnected or plug in the
connector connector between connector correctly
t 1 -Ground) junction block and
buzzer
2 Plug in the buzzer Terminal voltage System voltage 0 V Open harness wire Repair the harness
connector. of control unit or disconnected or plug in the
Unplug the harness side connector between connector correctly
connector from the connector buzzer and control
control unit (20-Ground) unit
BODY - Troubleshootinn 23-23
I 3. Release Switch (driver’s side), Buckle Switch, Outer Switch

-
Circuit I
1
AUTOMATIC SEAT BELT CONTROL UNI
1
RELEASE SWITCH BUCKLE
(LEFT SIDE) SWITCH
1
19A0345

Step Cause Remedy
lelease switch (driver’s side)
1 Unplug the Terminal-to-ground 0 Q mcl Open harness wire Repair the harness
“release” switch continuity of or disconnected or plug in the
connector. “release” switch connector between connector correctly
harness side “release” switch
connector and ground
(1 -Ground)
Improper ground Correctly connect
connection to ground
2 Plug in the Terminal-to-ground 0 Q when slide Remains Defective Replace the driving
“release” switch continuity of anchor is not in OQorooQ “release” switch device assembly.
connector. control unit the “release” (Refer to P.23-94.1
Unplug the harness side (switch ON) range.
connector from the connector Open harness wire Repair the harness
control unit. Move (5-Ground) ca g when slide or disconnected or plug in the
the slide anchor. anchor is in the connector between connector
“release” (switch control unit and correctly.
OFF) range. “release” switch

Step Cause RemI
Buckle switch
1 Unplug the Terminal-to-ground 0 Q Open harness wire Repair the

connector from the continuity of between buckle
buckle switch. buckle switch switch and ground
harness side
connector Improper ground Correctly c
(2-Ground) connection to ground
2 Plug in the buckle Terminal-to-ground 0 n Open harness wire Repair the

switch connector. continuity of between control
Unplug the control unit unit and buckle
connector from the harness side switch
control unit. connector
Leave the lap belt (2-Ground) Defective buckle Replace th
unfastened switch buckle.
(buckle switch ON). (Refer to F
3uter switch
1 Unplug the Terminal-to-ground 0 Q wfl Open harness wire Repair the

connector from continuity of outer between outer
the outer switch. switch harness switch and ground
side connector
L.H. Improper ground Correctly c
(2-Ground) connection to ground
R.H.
(4-Ground)
2 Pull out and Terminal-to-ground 00 0 from the Resistance remains Defective outer Replace thl
retract the continuity of outer belt’s fully Ogorcon switch retractor
shoulder belt. switch side retracted position or changes from (for should1
connector until belt is pulled ofltocon (Refer to F
L.H. (l-2) out approx. or from 00 62
R.L. (3-4) midway (outer to 0 62 at points
switch OFF) other than the
0 0 from the approx. midway
approx. midway pulled out position
pulled out position
until belt is pulled
out fully (outer
switch ON)
3 Attach the Terminal-to-ground 0 62 wdl Open harness wire Repair the

shoulder belt to continuity of between control
the slide anchor control unit unit and outer
(outer switch ON). harness side switch
Plug in the connector
connector to the L.H.
outer switch. (3-Ground)
Unplug the R.H.
connector from the (I 4-Ground)
control unit.
BODY - Troubleshootinn 23-25
4. Door Latch Switch, Fasten Switch, Release Switch (passenger’s side) Circuit
_-
AUTOMATIC SEAT BELT CONTROL UNIT

I ,
-- -----_ -
1 I
" 4 " 2
I
I
ifs I I
I I
I I
FASTEN I
SWITCH I I
(RIGHT
SIDE)
I
--_-
,,6 4,l
_--_---- J I
5 2s I
I
7,~-15,L--- _ _ _ _ _ --J
m
I
(1) Driver’s side

Step Cause Remedy
1 Unplug the door Continuity of door Between terminals Remains Door latch switch Replace the door
latch switch latch switch 2 and 3 OL4orooQ damaged latch switch
connector. (2-3, I-3) 0 0 when (Refer to P.2394.)
Open and close door is open
the door 00 il when door
is closed
Between terminals
1 and 3
OQ Q when door
is open
0 il when
door is closed
2 - Terminal-to-ground 0 Q wi-2 Open harness wire Repair the harness

continuity of door or disconnected or plug in the
latch switch connector between connector correctI\
harness side door latch switch
(3-Ground)
improper ground Correctly connect
3 Connect the door Terminal-to-ground 0 0 when door is Remains Open harness wire Replace the
latch switch continuity of open Ogoroon or disconnected harness or plug in
connector. control unit w 0 when door is connector between the connector
Unplug the harness side closed control unit and correctly.
connector from the connector door latch switch
control unit. (6-Ground)
Open and close
the door.
4 Unplug the Terminal-to-ground 00 Q when door is Remains Open harness wire Repair the harness
“fasten” switch continuity of the open OgorooQ or disconnected or plug in the
connector. “fasten” switch 0 s2 when door is connector between connector correctly
Open and close harness side closed “fasten” switch
the door. connector and door latch
(6-Ground) switch
5 Plug in the Terminal-to-ground 00 s2 when slide Remains Defective “fasten” Replace the driving
“fasten” switch continuity of anchor is in the Ogoraog switch device assembly
connector. control unit “fasten” range
Close the door. harness side (“fasten” switch
connector OFF)
(4-Ground) 0 !I when slide
anchor is not in the
“fasten” range
(“fasten” switch
ON)
BODY - Troubleshootins
(21 Passenger’s side

Step Cause Remedy
1 Unplug the door Continuity of door Between terminals Remains Door latch switch Replace the door
latch switch latch switch 2 and 3 OnorwQ damaged latch switch
connector. (2-3, I-3) 0 Q when door (Refer to P.23-94.)
Open and close the is open
door w 61 when door
is closed
Between terminals
1 and 3
w Q when door
is open
0 h2 when door
is closed
2 - Terminal-to-ground 0 0 Wi-l Open harness wire Repair the harness

continuity of the or disconnected or plug in the
door latch switch connector between connector correctly
harness side door latch switch
(3-Ground)
Improper ground Correctly connect
3 Connect the door Terminal-to-ground 0 0 when door is Remains Open harness wire Repair the harness
latch switch continuity of the open OQorwQ or disconnected or plug in the
connector. “release” switch w Q when door is connector between connector correctly
Unplug the harness side closed “release” switch
connector from the connector and door latch
“release” switch. (I -Ground) switch
Open and close the
door.
,+-
4 Connect the Terminal-to-ground 0 tl when door is Remains Defective “release” Replace the driving
“release” switch continuity of open and slide OQorwQ switch device assembly.
connector. control unit anchor is not in the (Refer to P.23-94.)
Unplug the harness side “release” range
connector from the connector (“release” switch
control unit. t 16-Ground1 ON) Open harness wire Repair the harness
Open and close the w !J when door is or disconnected or plug in the
door. closed and slide connector between connector correctly.
anchor in the control unit and
“release” range “release” switch
(“release” switch
OFF)
5 Unplug the Terminal-to-ground w Q when door is Remains Open harness wire Repair the harness
“fasten” switch continuity of the open ODorwQ or disconnected or plug in the
connector. “fasten” switch 0 0 when door is connector between connector correctly.
Open and close the harness side closed “fasten” switch
door. connector and door latch
(6-Ground) switch
6 Connect the Terminal-to-ground 0 0 when door is Remains Defective “fasten” Replace the driving
“fasten” switch continuity of closed and slide Oh2orwQ switch device assembly
connector. control unit anchor is not in the (Refer to P.23-94.)
Open and close the harness side “fasten” range
door. connector (“fasten” switch
(I 5-Ground) ON)
w 62 when door is Open harness wire Repair the harness
closed and slide or disconnected or plug in the
anchor is in the connector between connector correctly.
“fasten” range control unit and
(“fasten” switch “fasten” switch
OFF)
5. Motor Power Supply and Drive Circuit
S U B FUSI;LE LINK @
I
r- Vehicles with A.B.S.
,---Vehicles without A
AUTOMATIC
SEAT BELT
BELT MOTOR MOTOR
2 (LEFT SIDE) (RIGHT SIDE)
n
..
I n
AUTOMATIC SEAT
BELT MOTOR RELAY AUTOMATIC SEAT
(LEFT SIDE) BELT MOTOR RELAY
(RIGHT SIDE)
AIITnhAATlr CFAT r!
1310344
Step
T Check method Judgement T
Cause Remedy
1 Unplug the motor Terminal-to-ground 0 62 WQ Open harness wire Repair the harness
relay connector. continuity of between motor
harness side relay and ground
connector
(5-Ground) Improper ground Correctly connect
Harness side System voltage ov Open harness wire Repair the harness
terminal voltage or disconnected or plug in the
of motor relay connector between connector correctly
(Z-Ground, fusible link and
6-Ground) motor relay
Plug in the motor Terminal voltage System voltage ov Open harness wire Repair the harness
relay connector. of control unit or disconnected or plug in the
Unplug the harness side connector between connector correctly
connector from connector motor relay and
control unit. L.H. control unit
(8-Ground,
g-Ground) Defective motor Replace the driving
R.H. relay device assembly.
(18-Ground, (Refer to P.23-94.)
1 g--Ground) ,
BODY - Troubleshooting
AUTOMATIC SEAT BELT COMPONENTS LOCATION
.-
WA0734
Automatic seat belt control unit C Fasten switch A

Automatic seat belt motor E Key reminder switch I
Automatic seat belt motor relay D Outer switch F
Buckle switch G Seat belt warning light J
Buzzer K Release switch H
Door latch switch B - -
A
0(:
P
Automatic seat
belt control unit
Automatic seat
1680745
Ovter switch I
19A034(
reminder switch
BODY - Service Adjustment Procedures 23-31
HOOD ADJUSTMENT N23FAAK
1. Loosen the hood mounting bolts, and then adjust the hood
by moving it so that the clearance is equal on all sides.
2. Turn the hood bumpers, adjust the height of the hood.
3. Loosen the food latch mounting bolts, and move the food
switch to adjust the attachment between the food switch
and food striker.
16A0366
LIFTGATE ADJUSTMENT N23FCAE
1. Loosen the liftgate hinges mounting bolts, and then adjust

the liftgate by moving it so that the clearance is equal on all
sides.
2. Loosen the liftgate latch mounting bolts, and move the

liftgate latch to adjust the attachment between the liftgate
latch and liftgate striker.
FUEL FILLER DOOR ADJUSTMENT N23FDAE
Loosen the fuel filler door mounting screw and adjust the fuel
filler door so that the clearance around the fuel filler door is even
without any height differences.
10A0370
23-32 BODY - Service Adjustment Procedures
DOOR ADJUSTMENT NZBFEAF
1. Use the special tool to loosen the hinge mounting bolts on Lc

the body side, and then adjust the clearance around the door _
so that it is uniform on all sides.
Caution
Attach protection tape to the fender edges where the
hinge is installed.
2. When the hinge is replaced, loosen hinge mounting bolts on

door side and adjust alignment of fen,der panel with front
door panel.
3. Loosen door striker mounting screws to adjust alignment of
door panel.
4. Increase or decrease the number of shims and move striker
to adjust engagement of striker with door latch.
DOOR GLASS ADJUSTMENT NZSFFAK
1. Remove the door trim and waterproof film. (Refer to P.23

-65.)
2. Loosen the installation bolt of the window regulator ,%
assembly; then move the upper installation back and forth -
and adjust the tilted angle of the glass.
‘C 16A0711
DOOR INSIDE HANDLE PLAY CHECK N23FQAH
If the door inside handle play does not conform to the standard
value, check the door inside handle or door latch assembly, and
replace if necessary.
Standard value (A): 2.5-8.5 mm (.09-.33 in.)
18AO38t
DOOR OUTSIDE HANDLE PLAY CHECK N23FHAH
If the door outside handle play does not conform to the standard
value check the door outside handle or door latch assembly, and
replace if necessary.
Standard value (B): 2.5-6.5 mm (.09-.25 in.)
4
BODY - Service Adiistment Procedures 23-33
Front floor pan FLOOR PAN INSPECTION N23FlAC
A common result of body leaks is a soaked floor mat pad or

carpet, and it’s not unusual to find that the water is getting in
through the floor pan to some other low point in the body. It is
possible however, for water to enter higher up and run
downward to soak the mat.
Since a soaked mat should be removed for drying, it’s a good
way to start your check. Of course, mat removal means you’ll
have to take off door sill plates and pull out seats or seat cushion.
But, this gives you a clear field for action so you can check body
18AO510
seam sealing and the plugs in the floor pan.
It’s usually not practical to water test for floor pan or
?ear floor pan wheelhousing leaks unless a special underbody water spray
arrangement is available. As an alternate, the best way to locate
these leak points is to look for rusty seam edges or other traces
of leaks after the mats and cushions are removed. Traces of mud
are an indication that the water is coming in from below.
lOA
WATER TEST N23FPABs
1. Close roof lid tightly.

2. Hold hose upward and adjust water fountain to about 50 cm
(20 in.) high.
lW391
3. Pour water over the roof from about 30 cm (12 in.) above
roof for more than 5 minutes.
4. While pouring water, check for leak around roof lid.
5. In the event of leakage, check drain hose, weatherstrip
contact and others.
23-34 BODY - Hood
HOOD N23HAA8
18A0438
15 18AO751 L
Removal 5
Hood lock release cable removal steps
1.Bumper l 12. Hood lock release handle
2.Hood weatherstrip w 13. Hood latch
3.Heat protector 14. Protector
4.Hood weatherstrip 15. Hood lock release cable
Headlight hood protector
5.
I)+ 6 .Bumper Hood removal steps
7.
Hood support rod ;f3: “,;n,yction for washer tube and nozzle
8.Bumper
9. Hood switch <Vehicles with Hood hinge removal steps
theft-alarm system >
10. Bumper 17: ig?ction f o r w a s h e r t u b e a n d n o z z l e
11. Bumper bracket
l *I 12. Hood lock release handle Windshield wiper arms (Refer to GROUP
l 13. Hood latch 8-Windshield Wiper.)
NOTE
18. Front deck garnish
(1) Reverse the removal procedures to reinstall. ,*I 19. Hood hinge
INSPECTION
1 HOOD SWITCH
(I 1 Disconnect the hood switch connector.
(2) Check the continuity between the terminal.
WA0754 lBRO665 NOTE

m indicates that there is continuity between the terminals.
BODY - Hood 23-35
SERWCE POINTS OF INSTALLATION
19. APPLICATION OF GREASE TO HOOD HINGE/IS. HOOD
LATCH/12. HOOD LOCK RELEASE HANDLE
Apply multipurpose grease to all moving parts.
Grease: MOPAR Multipurpose Grease Part No.
6. INSTALLATION OF BUMPER
Install the bumper so that the amount of projection from the
front end upper bar is as shown in the illustration.
Front end upper bar

18AO392
23-36 BODY - Liftgate
LIFTGATE N230AAT
REMOVAL AND INSTALLATION /
11-16 Nm
16
/
9-14 Nm ’
7-10 ft.lbs.
“‘/- -$j
7-11 Nm
5-8 ft.lbs.
Removal
WA0743
1. Bumper
2. Liftgate damper (upper) Liftgate lock release handle removal steps
3. Liftgate outer weatherstrip Scuff plate (driver’s side)
4. Liftgate damper (lower) (Refer to P.23-85.)
5. Liftgate opening weatherstrip 15. Release handle cover
Liftgate hinge removal steps w 16. Liftgate lock release handle
Headlining (Refer to P.23-89.1 Liftgate latch removal steps
6. Connection for rear washer tube Rear end trim (Refer to P.23-85.)
Center pillar trim (driver’s side) (Refer to 10. Liftgate switch connector <Vehicles with
Quarter trim (driver’s side) 3 P.23-85.) theft-alarm system >
7. Connection for liftgate wiring harness ,4 1 1. Liftgate latch
8. Liftgate
9. Liftgate hinge Liftgate lock cylinder removal steps
Rear end trim (Refer to P.23-85.1
Liftgate removal steps 12. Liftgate unlock switch <Vehicles with
6. Connection for rear washer tube theft-alarm system >
Center pillar trim (driver’s side) (Refer to 13. Retainer
Quarter trim (driver’s side) 1 P.23-85.) 14. Liftgate lock cylinder
7. Connection for liftgate wiring harness Liftgate striker removal steps
8. Liftgate
Liftgate trim (Refer to P.23-86.)
Liftgate lock release cable removal steps 18. Liftgate striker
Rear seat (Refer to P.23-93.) Liftgate stopper removal steps
Scuff plate (driver’s side)
Quarter trim (driver’s side) (Referto Rear side trim (Refer to P.23-85.)
Rear end trim P.23-85.) c* 19. Liftgate stopper
Rear side trim 1
l a 11. Liftgate latch NOTE
15. Release handle cover (1) Reverse the removal procedures to reinstall.
l + 16. Liftgate lock release handle (2) 4* : Refer to “Service Points of Removal”.
17. Liftaate lock release cable (3) l * : Refer to “Service Points of Installation”.
BODY - Liftnate 23-37
19. REMOVAL OF LIFTGATE STOPPER
Caution
1. Never try to disassemble the liigate gas spring or
bum it.
2. Always bore a hole in the gas spring to release the
interior gas before the spring is discarded.
INSPECTION
LIFTGATE SWITCH
(I 1 Unlock the liftgate latch.
(2) Check the continuity between the terminals.
Terminal 1 2
Liftgate latch locked

Liftgate latch unlocked 0 0
NOTE
o(> indicates that there is continuity between the terminals.
LIFTGATE LOCK CYLINDER SWITCH
Check to be sure that there is continuity between connector
terminals 1 and 2 when the switch part shown in the illustration
is not pressed, and that there is no longer continuity when it is
pressed.

16.APPLlCATlON O F G R E A S E T O LIFTGATE L O C K
RELEASE HANDLE/ 11. LIFTGATE LATCH
23-38 BODY - Fuel Tank Filler Door
FUEL TANK FILLER DOOR N23JAA0

l Installation of Rear Side Trim,
Pre-removal Operation Quarter Trim and Scuff Plate
e Removal of Rear Seat (Refer to P.23-85.)
(Refer to P.23-93.) 0 Installation of Rear Seat
0 Removal of Rear Side Trim, Quart- (Refer to P.23-93.)
er Trim and Scuff Plate. 0 Fuel Filler Door Adjustment
(Refer to P.23-85.) (Refer to P.23-31.)
Removal steps 16A0462

l C 1. Fuel filler door
2. Fuel filler door hook
3. Release handle cover NOTE
l + 4. Fuel filler door lock release handle (I 1 Reverse the removal procedures to reinstall.
5. Fuel filler door lock release cable (2) l * : Refer to “Service Points of Installation”.

4. APPLICATION OF GREASE TO FUEL FILLER DOOR LOCK
RELEASE HANDLE/l. FUEL FILLER DOOR
BODY - Front Bumper 23-39
FRONT BUMPER N232AAU

< Normal type >
35-55 Nm
25-40 ft.lbs.
”
18A0725
Front bumper assembly removal steps Front bumper fascia removal steps
1. Splash shield mounting clip 1. Splash shield mounting clip
a* 2. Front garnish ** 2. Front garnish
3. Front turn signal light 3. Front turn signal light
4. Front combination light 4. Front combination light
5. Air intake cover 5. Air intake cover
6. Front bumper assembly 7. Fascia upper plate
7. Fascia upper plate 9. Front bumper fascia
8. Front bumper reinforcement assembly NOTE
9. Front bumper fascia (I 1 Reverse the removal procedures to reinstall.
(2) 4, : Refer to “Service Points of Removal”.
(3) l : <Non-turbo>

2. REMOVAL OF FRONT GARNISH
Refer to P.23-47.
23-40 BODY - Front Bumper
c Large type >
35-44 Nm
25-32 ft.lbs.
c4 WA0726
Front bumper assembly removal steps Front bumper fascia removal steps
1, Splash shield mounting clip 1. Splash shield mounting clip
2. Front garnish 4* 2. Front garnish
4* 3. Front turn signal light
3. Front turn signal light
4. Front combination light 4. Front combination light
5. Front fog light 5. Front fog light
6. Fog light bracket 8. Fascia upper plate
7. Front bumper assembly 10. Front bumper fascia
8. Fascia upper plate
9. Front bumper reinforcement assembly Fr)?everse the removal procedures to reinstall.
10. Front bumper fascia - (2) +I) : Refer to “Service Points of Removal”.

Refer to P.23-47.
BODY - Front Bumper 23-41
< Normal type >
Disassembly steps
w l C 1. Bumper absorber
2. Fascia upper plate 18AO723
3. Lower plate NOTE
4. License plate bracket (1) Reverse the disassembly procedures to reassemble.
5. Front bumper reinforcement (2) 4, : Refer to “Service Points of Disassembly”.
6. Front bumper fascia (3) l : Refer to “Service Points of Reassembly”.

1. REMOVAL OF BUMPER ABSORBER
Caution
1. Do not attempt to repair a bumper absorber that has
been compressed in an accident; replace it with a new
one.
2. Before discarding the bumper absorber, drill a 3 mm
(. 13 in.) diameter hole to discharge the gas contained
in the unit.
3. If the bumper absorber is to be’discarded, do not burn
it.
1. INSTALLATION OF BUMPER ABSORBER
If the squareness between the front bumper reinforcement
and the bumper absorber is improper, adjust it by putting a
spacer between them.
18*0426
23-42 BODY - Front Bumper
< Large type >
17-26 Nm
12-19 ftlbs.
Disassembly steps
** l 4 1. Bumper absorber
2. Fascia upper plate
3. Lower plate WA0724
NOTE
4. License plate bracket (1) Reverse the disassembly procedures to reassemble
5. Front bumper reinforcement (2) +e : Refer to “Service Points of Disassembly”.
6. Front bumper fascia (3) l + : Refer to “Service Points of Reassembly”.

Caution
one.
in the unit.
3. If the bumper absorber is to be discarded, do not bum
it.
1. INSTALLATION OF BUMPER ABSORBER
If the squareness between the front bumper reinforcement
and the bumper absorber is improper, adjust it by putting a
spacer between them.
18410426
BODY - Rear Bumper 23-43
REAR BUMPER N23ZAAV

< Normal type >
0 Removal of Rear End Trim

(Refer to P.23-85.)
JI
0 lnstallatron of Rear End Tnm
18A0452
Rear bumper assembly removal steps Rear bumper fascia removal steps
2. Rear panel garnish 2. Rear panel garnish
3. Rear combination light 3. Rear combination light
4. Connection for license plate light wiring 6. License plate light harness connector
harness and body wiring harness 7. Back-up light harness connector
5. Rear bumper assembly 8. Fascia plate upper
8. Fascia plate upper 10. Fascia plate lower
9. Rear bumper reinforcement assembly 11. Rear bumper fascia
10. Fascia plate lower NOTE
11. Rear bumper fascia Reverse the removal procedures to reinstall.
23-44 BODY - Rear Bumper
< Large type >
]
0 lnstallatron of Rear End Tnm
18AO722
Rear bumper assembly removal steps Rear bumper fascia removal steps
2. Rear panel garnish 2. Rear panel garnish
3. Rear combination light 3. Rear combination light
4. Connection for license plate light wiring 6. License plate light harness connector
harness and body wiring harness 7. Back-up light harness connector
5. Rear bumper assembly 8. Fascia plate upper
8. Fascia plate upper 10. Fascia plate lower
9. Rear bumper reinforcement assembly 11. Rear bumper fascia
10. Fascia plate lower
11. Rear bumper fascia NOTE
BODY - Rear Bummer 23-45
< Normal type >
Disassembly steps
1. License plate light
2. Back-up light
3. Rear side marker light
4. License plate light wiring harness
5. Bumper absorber
6. Rear bumper reinforcement NOTE
7. License plate bracket (1) Reverse the disassembly procedures to reassemble.
8. Rear bumper fascia (2) +* : Refer to “Service Points of Disassembly”.

Caution
one.
in the unit.
3. If the bumper absorber is to be discarded, do not burn
it.
23-46 BODY - Rear Bumper
< Large type >
5
17-26 Nm
18A0721
Disassembly steps
1 License plate light
2. Back-up light
3. Rear side marker light
4. License plate light wiring harness
4* 5. Bumper absorber
6. Rear bumper reinforcement
7. License plate bracket
8. Rear bumper fascia

Caution
been compressed in an accident; replace it with a new F---
one. -
2. Before discarding the bumper absorber, drill a 3 mm -z
(. 13 in.1 diameter hole to discharge the gas contained
in the unit.
3. If the bumper absorber is to be discarded, do not burn
it.
BODY - Garnishes 2347
GARNISHES
N2iRW
~w REMOVAL AND INSTALLATION i‘\
18Ao435
Front garnish removal Rear panel garnish removal steps

1. Front garnish Rear end trim
4m (Refer to P.23-85.)
Front deck garnish removal steps 3. Rear panel garnish
Windshield wiper arms
(Refer to GROUP 8-Windshield Wiper.) NOTE
2. Front deck garnish (1) Reverse the removal procedures to reinstall.
(2) l I) : Refer to “Service Points of Removal”.

Remove the mounting screws, and pressing downward the
claws of the clips, remove the front garnish.
23-48 BODY - Moulding
MOULDING
67 6
WA0421
4, 1. Drip moulding
4, 2. Windshield upper moulding
l * 3. Quarter window moulding lower
** 4. Quarter window moulding upper
4* 5. Quarter window moulding front
l * 6. Liftgate moulding lower
l + 7. Liftgate moulding upper
a* 8. Liftgate moulding side
+* l + 9. Side protect moulding fender NOTE
+e I)+ 10. Side protect moulding front door (1) ** : Refer to “Service Points of Removal”.
4, 11. Side protect moulding quarter (2) I)+ : Refer to “Service Points of Installation”.

1. REMOVAL OF DRIP MOULDING
Refer to P.23-72.
2. REMOVAL OF WINDSHIELD UPPER MOULDING
Refer to P.23-58.
BODY - Moulding 23-49
3. REMOVAL OF QUARTER WINDOW MOULDING LOWER/
4. QUARTER WINDOW MOULDING UPPER/B. QUARTER
WINDOW MOULDING FRONT
Refer to P.23-61.
6. REMOVAL OF LIFTGATE MOULDING LOWERI7. LIFT-
GATE MOULDING UPPER/8. LIFTGATE MOULDING
SIDE
Refer to P.23-62.
9. REMOVAL OF SIDE PROTECT MOULDING FENDER/IO.

SIDE PROTECT MOULDING FRONT DOOR
(1) Using the plastic trim tool, pry off the side protect
moulding.
(2) Using the plastic trim tool, scale off the both-side
adhesive tape which sticks to the body.
11. REMOVAL OF SIDE PROTECT MOULDING QUARTER

(1) Remove the rear side trim. (Refer to P.23-85.)
(2) Remove the motor section of the driving device
assembly. (Refer to P.23-94.)
(3) After removing the mounting nuts, pry off the side
protect moulding quarter with the plastic trim remover.

9. INSTALLATION OF SIDE PROTECT MOULDING FEN-
DER/10. SIDE PROTECT MOULDING FRONT DOOR
(1) Wipe off application surface of body with clean cloth
dampened with degreaser (MOPAR SUPER KLEEN or
equivalent).
NOTE
After wiping surface, leave surface as it is to volatilize
degreaser.
1 (2) Using an infrared light or similar instrument, heat the

body painted surface and the side protect moulding.
Heating temperature
Body painted surface..... 25-55OC (77-131 OF)
Side protect moulding . . . . 25-40°C (77- 104OF)
23-50 BODY - Moulding
(3) Remove backing paper from adhesive tape, and apply
adhesive tape as shown in the illustration.
6
Side protect moulding adhesive tape:
V
3M ATD Part No.6383 or equivalent
Side protect moulding fender ’
(4) Attach the side protect mouldings at the places shown
in the illustration.
Side protect moulding front door (5) Use hand roller or similar tool to apply even pressure to
entire surface of moulding.
NOTE
Press moulding ends firmly against the body surface.
Side protect moulding mounting positions
Front door
Section A-A or front fender
panel
i
Section B-B
WA0400
BODY - Fender
FENDER u23KAAr
:- REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation

0 Removal of Front Garnish 0 Installation of Side Air Dam
l Removal of Front Turn Signal Light l Installation of Headlight Lower
and Front Combination Light Bezel
(Refer to GROUP 8-Front Combi- (Refer to GROUP 8-Headlight)
nation Light) 0 Installation of Front Turn Signal
l Removal of Headlight Lower Bezel Light and Front Combination Light
(Refer to GROUP 8-Headlights) (Refer to GROUP 8-Front Combi-
l Removal of Side Air Dam nation Light)
(Refer to P.23-74.) 0 Installation of Front Garnish
L
(Refer to P.23-47.)
L J
-.
Removal steps
1. Front splash shield extension
l 2. Front splash shield
l C 3. Front fender panel
NOTE
(2) .a : Refer to “Service Points of Installation”.
(3) l 1 : This shows a tightening torque of 2.0-2.2 Nm
(1 .4-l .6 ft.lbs.1.
(4) l 2 : This shows a tightening torque of 4-6 Nm
( 2 - 4 ft.lbs.1.
View A Sealant SERVICE POINTS OF INSTALLATION

3. APPLICATION OF SEALANT TO FRONT FENDER PANEL
When installing the fenders, apply specified sealant between
the fenders and the body panels, so that there are no gaps
when the fenders are mounted.
Specified sealant: MOPAR Silicone Rubber Sealer Part
23-52 BODY - Fender
2. APPLICATION OF ADHESIVE TO SPLASH SHIELD
When installing the splash shield, apply specified adhesive to e
the flange part of the fender. 4
Specified adhesive: MOPAR Silicone Rubber Sealer
Part No.4026070 or Auto Glass
Adhesive and Sealer Part
BODY - Loose Panel
LOOSE PANEL N22SAAK ,

, Frbnt piI@ (LH),/
Front deck
crossmember +A /
v tray
Deck crossmember stay
/ ‘-9-14 Nm
Front
I 7-10 ftlbs. WA0463
slaememoer
(RH)
m Waterproof plate
\K?%--
WA0471
-.
/-c---x /
Headlight support
, Headlight support
I I Hood lock support
WA.0741 , _ Headlight support
e Dumper, 18AO484
MA0742
e duct
WA0472
23-54 BODY - Window Glass
WINDOW GLASS N23LAAB
GENERAL
The windshield and liftgate window glass are attached by an urethane-base adhesive to the window frame.
This adhesive not only provides improved glass holding and sealing, but also permits use of body openings
having a greater structural strength.
ADHESIVE, PRIMER AND RESERVE ITEMS
Items Applications Quantity

Adhesive, Primer
Adhesive: As required
3M Super Fast Urethan Part No.8609
or equivalent
Primer: As required
3M Super Fast Urethan Primer
Reserve items
Dispensing nozzle One
Wire (dia. x length) for cutting adhesive Lir,“$c;s onfi wire
(62 in. x 3.3 ft.)
Adhesive gun for adhesive application One
Isopropyl alcohol for cleaning jointing surfaces As required
Wiping rags As required
Sealer for prevention of water leaks and As required
gathering after adhesive application
Isopropyl alcohol for cleaning As required
Glass holder Two
Spacers (Service Part) As required
Window moulding assembly One
(Service part)
Tectyl 506T (Valvoline Oil Company) As required
BODY - Window Glass 23-55
WINDSHIELD INSTALLATION PROCEDURE
Removal of moulding
(Wire)
Body Glass
- - e-e
+ -t
I
Finishing of adhesive
surface
If reusing glass;
r - - - - - - - - - 1 ---s------ - -‘-,
IRemoval of adhesive and dam Ir
L---------r---s----------
e-e _---mm,- __-_--_ 1,

(Paint thinner)
I
-*I
I
II I (Isopropyl alcohol)
_-
ship of glass to body
(glass blackout primer)
I
pi&g
Application of solvent
(Isopropyl alcohol)
I I
I
-1 I- - - (urethane adhesive)
_ Installation of glass
to body
I
Cleaning of attaching
surface
1
If water leaks
--------------~
p%zG&pJ
(Isopropyl alcohol)
23-56 BODY - Window Glass
Recommended tool
REPLACEMENT OF MOULDING (WINDSHIELD
UPPER MOULDING AND QUARTER WINDOW p;
Make the tool by N22LABc -
MOULDING FRONT)
1. Remove the mouldings. (Refer to P.23-58, 61.)
2. To cut the existing adhesive, make a tool such as the one
shown.
3. Using the tool, scoop out the existing adhesive.

Caution
Take care not to remove more adhesive than neces-
Windshield glass
sary, and not to scratch the glass or body.
Roof panel scoop out

this portion.
iiiii- ,.:::i:::::::::::i.
p:://jiiiig;iiiijjiiij
::::::::::iiiiiii.::;
I&
Quarter Quarter
panel window
glass
WA0870
4. Cut away part of the new moulding and provisionally attach

the moulding. Check to be sure that it fits closely to the
Windshield surface.
upper 5. A coating of the specified primer should be applied to the
moulding moulding.
Primer Specified primer: 3M Super Fast Urethan Primer Part
- - - ---. C u t here. Caution
Do not touch the surfaces that are coated with primer.
4%
Quarter
window
moulding
front
>/yere.
MAO672
-
BODY - Window Glass 23-57
6. Apply a coating of the specified adhesive where shown in
the illustration, and then install the moulding before the
Windshield adhesive hardens.
upper
moulding Specified adhesive: 3M Super Fast Urethan Part
7. Scrape away excessive sealant forced out during installa-
tion of the moulding from the glass or body and wipe the
surfaces clean with MOPAR SUPER KLEEN or equivalent.
8. After completion of installation, leave the moulding undis-
turbed until the adhesive hardens.
Additional
Quarter window
moulding front
-.
23-58 BODY - Windshield
WINDSHIELD NZBLBAR

0 Removal of Hood
(Refer to P.23-34.)
0 Removal of Wiper Arm ,
( R e f e r t o G R O U P &Windshield
Wiper)
l Removal of Front Deck Garnish
(Refer to P.23-47.)
0 Removal of Front Headlining Trim
(Refer to P.23-89.)
0 Removal of Drip Moulding
(Refer to P.23-72.)
0 Installation of Drip Moulding
(Refer to P.23-72.)
0 Installation o f F r o n t H e a d l i n i n g
Trim
(Refer to P.23-89.)
l Installation of Front Deck Garnish
(Refer to P.23-47.)
l installation of Front Wiper Arm
(Refer to GROUP 8-Windshield
Wiper)
0 Installation of Hood
(Refer to P.23-34.)
ISA0466
Removal steps
1. Inside rear view mirror
2. Windshield upper moulding
a* 3. Windshield glass
4. Windshield glass spacer
Installation steps NOTE
4. Windshield glass spacer (1 I Reverse the removal procedures to reinstall.
l 2. Windshield upper moulding (2) +* : Refer to “Service Points of Removal”.
+a 3. Windshield glass (4) H : N o n - r e u s a b l e p a r t s
1. Inside rear view mirror

3. REMOVAL OF WINDSHIELD GLASS
(1) Using a sharp-pointed drill, make a hold in the adhesive
area of the windshield.
From inside the vehicle, insert one end of wire through
adhesive material applied to the upper edge of
windshield.
(2) Insert the other end of wire from inside the vehicle
through adhesive material applied to the lower edge of
windshield.
(3) Secure each end of wire to a piece of wood or similar
object.
(4) Carefully cut through adhesive by pulling wire along the
windshield from outsi,de the vehicle in a sawing motion.
Caution
In order to protect the body from damage, apply cloth
tape to all body areas around the installed glass before
cutting the adhesive.
BODY - Windshield
(5) Make mating marks on the glass and body if the glass
Glass holders is to be reinstalled.
NOTE
Use chalk or equivalent to make mating marks on the
glass and body.
(6) Take out the glass with glass holders.
NOTE
If the glass being removed is to be reinstalled, place it on
a protected bench or holding fixture.

2. INSTALLATION OF WINDSHIELD UPPER MOULDING/
3. WINDSHIELD GLASS
(1) Thoroughly remove the adhesive deposited on the
windshield glass and clean applying surface with
isopropyl alcohol.
Allow to dry for at least three minutes.
(2) Apply the specified primer to the entire bonding surface

of the glass, both to the inside surface and the edge of
the glass.
Allow to dry for five minutes.
Specified primer: 3M Super Fast Urethan Primer
Caution
Use care to avoid spilling primer solution on trim or a
painted surface. Wipe away any spilled solution
immediately, because the primer will damage trim or
painted surfaces. Do not touch the primer coated
,
surface.
(3) Use a cutter knife to cut away adhesive so that the
thickness is within 2 mm (.08 in.) around the entire
circumference of the body flange.
Finish the flange surfaces so that they are smooth.
Caution
Be careful not to remove more adhesive than
necessary, and also not to damage the paintwork on
the body surface with the knife. If the paintwork is
damaged, repair the damaged area with touch-up
paint or Tectyl.
(4) Degrease the bonding surface of the body with isopropyl
alcohol.
Allow to dry for at least three minutes.
(5) Attach the windshield upper moulding to the windshield
glass.
23-60 BODY - Windshield
(6) Using the adhesive gun, coat the specified adhesive on
the windshield glass mounting surface of the body
flange. Fi
Specified adhesive: 3M Super Fast Urethan Part -
NOTE
Cut the nozzle tip into a V shape to facilitate adhesive
SECT. B-B
(Other areas not illustrated are application. Adhesive material begins to cure after fifteen
SECT. A-A the same as those in cross aec- minutes’ when exposure to air.
tion A-A.)
(7) Using a glass holder, place the glass on the body

opening.
(8) Press the glass gently so that no adhesive appears.
Approx.
ISA0520 iSAo522&j Caution
SECT. C-C
(Other areas not illustrated are the same
1. Do not move the glass after installing them to the
as those in cross section A-A.1 body.
Nozzle tip 2. Place the glass in the previously marked position.
G Q
Approx 7 I 28) 3. Use care not to close the water groove (in the
Approx lower corner of the pinch weld flange) with
12 t.47
adhesive.
4. Wipe off any excessive adhesive that overflows.
1.3~0523 m m (in.) 181988
(9) Perform the water-test for the windshield.

Use cold water spray, being careful not to direct a
powerful stream of water on the new adhesive material.
Allow water to spill over the edges of the glass. If there ~
are leaks, apply sealant at the leak point(s).
s/
Caution
If it is necessary to move the vehicle, move it slowly.
(10)Using a clean, lint-free cloth liberally dampened iso-
propyl alcohol, wipe away dirt from the glass perimeter
and the body.
INSTALLATION OF WINDSHIELD WITH NEW ADHESIVE

ONLY
This method is recommended if there is a considerable loss of
adhesion between the old adhesive material and the body
opening, or body opening requires repair. All adhesive material
must be removed from the pinch-weld flanges.
1. Using a knife or similar tool, remove the old adhesive
material from the pinch weld flanges.
2. Using tape or some other suitable means, mark the bonded
areas of the body and the glass at several positions.
3. Using a clean, lint-free cloth liberally dampened with
isopropyl alcohol, prime the pinch-weld flange.
4. If the pinch-weld flange has been repainted, prime it with a
paint finish primer.
Caution
1. Do not use blackout glass primer on the pinch-weld q
flange.
2. If the pinch-weld flanges require painting, use a bake- L
on type paint.
5. For the rest of the service procedure, refer to Installation of
WINDSHIELD on P.23-59.
BODY - Quarter Window Glass 23-61
QUARTER WINDOW GLASS N22LEAK
@Removal of Rear Side Trim, Quarter
Trim. Center Pillar Trim and Rear
I Pillar’ Trim
(Refer to P.23-85.)
l kemoval of Side Air Spoiler
I
I (Refer to P.23-74.) I
ter Trim, Center Pillar Trim and Rear
Removal steps Installation steps

1. Quarter window moulding lower 5. Quarter window moulding clip
2. Quarter window moulding upper l + 3. Quarter window moulding front
3. Quarter window moulding front l * 4. Quarter window glass
4. Quarter window glass 2. Quarter window moulding upper
5. Quarter window moulding clip 1. Quarter window moulding lower
NOTE
(2) $ : Non-reusable parts
-I
Quarter window glass SERVICE POINTS OF INSTALLATION

3. INSTALLATION OF QUARTER WINDOW MOULDING
FRONT/4. QUARTER WINDOW GLASS
SECT.
B-B and C-C (1) Remove residual-sealant from the body and glass.
SECT. A-A (2) Degrease the body and glass, and coat primer.
(Refer to P.23-59.)
(3) Coat specified sealant on the indicated position of the
18AO521
glass.
Specified sealant: MOPAR Silicone Rubber Sealer
m m (in.)
18AO521 Part No.4626070 or Auto Glass
Adhesive and Sealer Part
(4) Mount the glass on the body.
23-62 BODY - Liftgate Window Glass
LIFTGATE WINDOW GLASS N22LDAK
*Removal of Liftgate Trim and Flange
Trim
(Refer to P.23-86.)
aRemoval of Air Spoiler
(Refer to P.23-74.)
*Installation of Air Spoiler
(Refer to P.23-74.)
*Installation o f Liftgate T r i m a n d I
Flange Trim
(Refer to P.23-86.)
Removal steps
I. Liftgate moulding upper
2. Liftgate moulding clip
3. Liftgate moulding lower WA0487
4. Liftgate moulding side
o* 5. Liftgate window glass
6. Liftgate moulding fastener
7. Liftgate moulding clip
Installation steps
7. Liftgate m o u l d i n g c l i p
6 . Liftgate moulding f a s t e n e r
M 4. Liftgate m o u l d i n g s i d e
w 5. Liftgate w i n d o w g l a s s NOTE
3. Liftgate m o u l d i n g l o w e r (1) l * : Refer to “Service Points of Removal”.
2. Liftgate m o u l d i n g c l i p (2) .+ : Refer to “Service Points of Installation”.
1. Liftgate m o u l d i n g u p p e r (3) q : Non-reusable parts

5. REMOVAL OF LIFTGATE WINDOW GLASS
Remove the quarter window glass in the same procedure as
the windshield glass. (Refer to P.23-58.)

4. INSTALLATION OF LIFTGATE WINDOW MOULDING
SECT. A-A SECT. B-B
(Other areas not illustrated are SIDE/5. LIFTGATE WINDOW GLASS
the same as those in cmss sec-
Compared with the windshield glass, adhesive is coated on
the different position but the working procedure is same.
(Refer to P.23-59.)
SECT. C-C
(Other areas not illustrated are the 1ar40525
same as those ,ncrms sectmn A-A )
m m (in.)
ISA0526
BODY - Door Assemblv
DOOR ASSEMBLY N22MAW
17-26
12-19
17-26
12-19
15A0511
Removal steps
1. Connection for door wiring harness 0 Removal of Cowl Side Trim
connector (Refer to P.23-85.)
*+ 2. Spring pin
3. Door assembly
l 4. Upper hinge l Installation of Cowl Side Trim
.c 5. Lower hinge (Refer to P.23-85.)
6. Striker 0 Door Adjustment
7. Striker shim
8. Door switch cap
9. Door switch
l * 10. Door check strap
NOTE
(2) I)+ : Refer to “Service Points of Instal$tion”.
23-64 BODY - Door Assembly
INSPECTION
DOOR SWITCH
Operate the switch, and check the continuity between the T
terminals.
TYPE A
ON-OFF
stroke 1 2 3
1*,,.$
18A0158 A 0
Open (ON) 0
Switch
Depressed (OFF)
NOTE
Type B
TYPEB
1 2
Open (ON) 0 0
ON-OFF Switch
stroke Depressed (OFF)
“1 / b
- 16PO192
NOTE
10. APPLICATION OF GREASE TO DOOR CHECK STRAP/
5. LOWER HINGE/A UPPER HINGE12. SPRING PIN
Apply multipurpose grease to all moving parts. A
Grease: MOPAR Multipurpose Grease Part No. ‘- -’
DOOR CHECK STRAP REPLACEMENT

k
1. Remove the door trim and waterproof film.
2. Press upward and remove spring pin.
3. Remove door check strap nuts. Remove door check strap.
lBA0459
4. With the identification mark upward, install door check strap.

5. After installation of the door check strap, apply a coating of
multipurpose grease to the door check strap slide surface
and the spring pin (at the places shown in the figure).
Identification mark
BODY - Door Trim and Waterproof Film 2345
DOOR TRIM AND WATERPROOF FILM
I
< Oriver’s seat side>
Power window provided vehicle %l PL

\
2i36~4
15AO514
< Passenaer’s seat side >
er window provkkd
Removal steps
l + 1. Clip
2. Door window regulator handle
3. Escutcheon
4. Door grip mounting screw
5. Pull handle box
l * 6. Door trim
7. P o w e r w i n d o w s w i t c h WA0513
8. Electrical remote control mirror switch
9. Door grip
10. Pull handle bracket NOTE
11. Door grip lower bracket (1) Reverse the removal procedures to reinstall.
12. Door trim bracket B (2) a* : Refer to “Service Points of Removal”.
13. Door trim bracket C (3) +* : Refer to “Service Points of Installa~lon”,
*c 1 4 . W a t e r p r o o f f i l m ( 4 ) + shows the installation position of trim Clip.
I
23-66 BODY - Door Trim and Waterproof Film/Door Glass and Regulator
1. REMOVAL OF CUP ‘. +i
Use a shop towel to remove the clip; and remove door _A
window regulator handle.
6. REMOVAL OF DOOR TRIM

If clip remains in mounting hole provided in door, rem ove it
by using tool manufactured as illustrated.

IbY I
Sealant
!I
14,APPLlCATlON OF SEALANT TO WATERPROOF FILM
Apply specified sealant at the position shown in the
illustration, and then attach the waterproof film. /r
Specified sealant: MOPAR Rope Caulk Sealer 3/ --‘I
16 X 80” roll Part No.4026044 or
equivalent
DOOR GLASS AND REGULATOR N23MCAW
IMOVAL AND INSTALLATION
l Removal of Door Trim and Water-
proof Film
(Refer to P.23-65.)
l Removal of Front Door Belt Line In-
ner Weatherstrip
(Refer to P.23-72.)
2.0-4-O Nm
1.5-3.0 ft.lbs.
Removal steps
1. Door window glass 0 Installation nf Frnnt lhnr Rnlt I inn
2. Door glass holder
*4 3 . F r o n t d o o r w i n d o w r e g u l a t o r
4. Front door rear sash l Installation of Door Trim and
NOTE
II ) Reverse the removal procedures to reinstall. 0 Door Window Glass Adjustment
12) l + : Refer to “Service Points of Installation”
BODY - Door Glass and Reaulator/Power Window 23-67
3. APPLICATION OF GREASE TO FRONT DOOR WINDOW
REGULATOR
POWER WINDOW N23MHAEa
71
l Door Window Glass Adjustment
<Driver’s seat side> < Passenger’s seat side >
1810469
Power window relay removal

1. Power window relay
Power window switch removal steps
Door trim (Refer to P.23-65.)
2. Power window main switch
3. Power window sub switch
Power window motor removal steps
Door trim and waterproof film
NOTE (Refer to P.23-65.)
(1) Reverse the removal procedures to reinstall. 4. Door window glass
(2) l + : Refer to “Service Points of Installation”. l + 5. Front door window regulator
INSPECTION
POWER WINDOW RELAY
Apply battery voltage to terminal 2, and check for continuity
when terminal 4 is grounded.
16l.0344 NOTE
3 4 16AO606 O-O indicates that there is continuity between the terminals.
23-68 BODY - Power Window
POWER WINDOW MOTOR
(1) Connect the motor terminal directly to the battery and
check to be sure that the slider moves smoothly.
(2) Also check to be sure that the slider moves in the opposite
direction when the battery polarity connections are
changed.
CIRCUIT BREAKER (INCORPORATED IN THE POWER

WINDOW MOTOR)
(1) Press the UP switch to fully close the window glass, and
continue to press the switch for 10 seconds.
(2) At the moment that the UP switch is released, press the
DOWN switch. The circuit breaker can be considered good
if at this time the door window glass begins to open within
60 seconds.
Power
POWER WINDOW MAIN SWITCH
window Check for continuity in accordance to the following connection
lock
switch table.
NOTE
BODY - Power Window/Door Handle and Latch 23-69
POWER WINDOW SUB SWITCH
Check for continuity in accordance 10 the following connection
table.
I-
NOTE

5. APPLICATION OF GREASE TO FRONT DOOR WINDOW
REGULATOR
Refer to P.23-67.
DOOR HANDLE AND LATCH N23MDAY
REMOVAL AND INSTALLATION c
Door inside handle removal

Door Inside Handle Plav Check
(Refer to P.23-32.1
l + 1. boor inside handie
Door outside handle and latch removal steps
Door Outside Handle Play Check
(Refer to P.23-32.)
2. Bolt
3. Door key cylinder unlock switch connector
(Vehicles with theft-alarm system)
4. Ring
5. Door lock key cylinder
l + 6. Door outside handle
7. Bellcrank holder mounting
bolt
.a 8. Door latch assembly
9. Door latch switch
(Vehicles for U.S.)
Pm-removal Operation
0 Removal of Door Trim and Water-
proof Film
(Refer to P.23-65.)
l Installation of Door Trim and
Waterproof Film
(Refer to P.23-65.) 1
NOTE
(I) Reverse the removal procedures to reinstall. ‘/
(2) *+ : Refer to “Service Points of Installation”. 1m
L
23-70 BODY - Door Handle and Latch/Central Door Lockina Svstem
INSPECTION
DOOR KEY CYLINDER UNLOCK SWITCH
The key cylinder unlock switch is normal if there is not continuity 7
between terminals 1 and 2 when the key is turned approx. 20” ’
clockwise or counterclockwise from the neutral position, and
there is continuity when it is turned further.
I .- .-- 1
18AO750 lBY3611 I,
INSPECTION
DOOR LATCH SWITCH
!- Operate the switch, and check the continuity between the

terminals.
II
T!3
1 2
3
18PO39i
NOTE

7. APPLICATION OF GREASE TO DOOR LATCH ASSEM-
BLY/5. DOOR OUTSIDE HANDLE/l. DOOR INSIDE rr,
HANDLE .< ‘
CENTRAL DOOR LOCKING SYSTEM N23ZDAI-I
REMOVAL AND INSTALLATION Cowl side

(right side) , ,
0 Removal of Door Trim and Water-
I proof Film
(Refer to P.23-65.) Door lock
0 Removal of Cowl Side Trim control
(Refer to P.23-85.) unit or
0 Removal of Knee Protector theft-alarm
(Refer to P.23-80.) control unit
0 Installation of Door Trim and
W aterproof Film
(Refer to P.23-65.)
l Installation of Cowl Side Trim
(Refer to P.23-85.)
0 Installation of Knee Protector
(Refer to P.23-80.)
I
BODY - Central Door Locking System/Door Runchannel 23-71
INSPECTION
DOOR LOCK ACTUATOR
(1) Place the rod in the LOCK position, apply the battery power
to the terminal i(l) for left or (3) for right1 and check to see
that when the terminal L(3) for left or (I) for right1 is
grounded, the rod moves to the UNLOCK position.
View A
(2) Then place the rod in the UNLOCK position, apply the battery
power to the terminal L(3) for left or (I 1 for right], and check
to see that when the terminal [(l ) for left or (3) for right1 is
18A0064
grounded, the rod moves to the LOCK position.
-
(3) Check to ensure that when the rod is placed in the UNLOCK
position, there is a continuity between the terminals 12) and
(41, and that when the rod is placed in the LOCK position,
there is no continuity.
DOOR LOCK RELAY
Check for continuity between terminals under the conditions
described below.
, 2 3 4 5 , 8
Continuity no voltage 0 0 o - - o
0
0 0
Continuity with voltage @- -----@

@--0
NOTE
(1) O-O indicates that there is continuity between the terminals.
(2) O---O indicates terminals to which battery voltage is applied.
DOOR RUNCHANNEL N23MEAN

0 Removal
_ -.. of Door Trim and Water-
proot Mm
(Refer to P.23-65.1
1 l Removal of Door’ Window Glass 1
I and Front Door Rear Sash I
(Refer to P.23-66.) I
l Installation of Door Window Glass
and Front Door Rear Sash
(Refer to P.23-66.1 I
l Installation of Dbor Trim and
Door window Runchannel
runchannel
18A0465
23-72 BODY - Door Moulding and Drip Line Weatherstrip/Door Mirror
DOOR MOULDING AND DRIP LINE WEATHERSTRIP NZBMFAK

Removal steps
1. Front door belt line inner weatherstrip
2. Front door belt line outer weatherstrip &
3. Front door outer opening weatherstrip
4. Drip moulding
5. Front door inner opening weatherstrip
Pre-removal
- ^ Operation
II_ -. .
l HemOVal ot Uoor I rim and Water-
proof Film
(Refer to P.23-65.)
.- _,
l Removal ot Door Mirror
NOTE
(I 1 Reverse the removal procedures to reinstall.
(2) +, : Refer to “Service Points of Removal”.

3. REMOVAL OF DOOR OUTER OPENING WEATHERSTRIP
Make a tool as shown in the illustration to remove the door
opening weatherstrip.
158E
-
DOOR MIRROR N23OAAM

4
Pre-removal Operation Electric remote

l Removal of Door Trim controlled mirror
(Refer to P.23-65.)
l Installation of Door Trim
(Refer to P.23-65.) 5
h-. Directly controlled
mirror
Removal steps
mr(ol*.
I. Knob (directly controlled mirror)
2. Inner delta cover
3. Door trim bracket NOTE
4. Door mirror Reverse the removal procedures to reinstall.
5. Mirror sub assembly
BODY - Door Mirror/Electric Remote Controlled Mirror Switch 23-73
INSPECTION
ELECTRIC REMOTE CONTROLLED MIRROR ASSEMBLY
Check to be sure that the mirror moves as described in the table
when each terminal is connected to the battery.
18AO425
DOWN 0 0
0 0
RIGHT 0 0
0 0
LEFT
IOI
ELECTRIC REMOTE CONTROLLED MIR-

ROR SWITCH N23QAAN
INSPECTION
ELECTRIC REMOTE CONTROLLED MIRROR SWITCH
Operate switches and check the continuity between terminals.
LEFT 0 0 0 0
0
RIGHT 0 0
NOTE
16P0109
- O-O indicates that there is continuity between the terminals.
. .
23-74 BODY - Aero Parts
AERO PARTS N23XAAH
WA0763
18A0764
lQA0479
Side air dam removal Rear air spoiler assembly (side) removal steps
l *l * 1. Side air dam (door) 6. Mast antenna
2. Air,dam clip 7. Mounting nut
+* l + 3. Side air dam (side sill) 8. Mounting insulator
l * l a 9. Rear air spoiler assembly (side)
Rear air spoiler assembly (center) removal steps 10. Air spoiler bracket assembly
Rear wiper Door air spoiler removal
(Refer to GROUP 8-Rear Wiper.)
Liftgate trim (Refer to P.23-86.) ,+ 1 1. Door air spoiler
High mounted stop light
(Refer to GROUP 8-Lighting System.) NOTE
4. Rear wiper grommet (1) Reverse the removal procedures to reinstall.
+w l c 5. Rear air spoiler assembly (center) (2) l + : Refer to “Service Points of Removal”.
12. Spoiler tape (3) l + : Refer to “Service Points of Installation”.
BODY - Aero Parts 23-75
1. REMOVAL OF SIDE AIR DAM (DOOR)/3. SIDE AIR DAM
(SIDE SILL)
(I 1 After the mounting screws are removed, apply the plastic
trim tool to the bonding and clipped areas to remove the
side air dam.
(21 Scale off the both-side adhesive tape with the plastic trim
tool.
\ 18A0245
5. REMOVAL OF REAR AIR SPOILER ASSEMBLY (CENTER)/

9. REAR AIR SPOILER ASSEMBLY (SIDE)
After the rear air spoiler mounting bolts or screws have been
removed, move the rear air spoiler to the rear of the vehicle,
remove the rear air spoiler from the tapping screws, and pull
off the rear air spoiler.

11. INSTALLATION OF DOOR AIR SPOILER
(I 1 After removal of oils and greases from the body side and
the door air spoiler side, warm the adhesive surface. (Refer
to the section concerning installation of the side air dam.)
(2) Remove backing paper from adhesive tape, and apply
adhesive tape as shown in the illustration.
Specified adhesive tape:
16A0765
3M ATD Part No.6383 or equivalent
(3) Use hand roller or similar tool to apply even pressure to
entire surface of door air spoiler.
NOTE
Press door air spoiler ends firmly against the body surface.
9. INSTALLATION OF REAR AIR SPOILER ASSEMBLY

(SIDE)/5. REAR AIR SPOILER ASSEMBLY (CENTER)
Install the rear air spoiler in position so that its clips are held
by the tapping screws.
NOTE
When the clip remains on the body side, securely attach the
18A0416
clip to the rear air spoiler, and mount them.
3. INSTALLATION OF SIDE AIR DAM (SIDE SILL)/1 . SIDE AIR
DAM (DOOR)
(I 1 Wipe off application surface of body with clean cloth
dampened with degreaser IMOPAR SUPER KLEEN or
equivalent).
NOTE
After wiping surface, leave surface as it is to volatilize
degreaser .
18A041C
23-76 BODY - Aero Parts
(2) Using an infrared light or similar instrument, heat the
body painted surface and the side air dam.
Heating temperature rt
Body painted surface . . . . . 25-55OC (77-131OF) -. ’
Side air dam . . . . . . . . . . . . . . . . 25-40°C (77-104OFI
WA0411
Side air dam (door) (3) Peel off the paper from the adhesive tape, apply specified
Adhesive adhesive and sealant at the places shown in the figure,
A
and attach to the body adhesive surface.
Specified adhesive tape: 3M ATD Part No.6383 or
Side air dam (side sill) equivalent
(4) Using a hand roller or similar tool, apply pressure to the
entire surface of the side air dam.
NOTE
ZBI Adhesive tape CZJI Adhesive tape
<Thickness: 1.2mm <Thickness: 3 mm
The ends of the side air dam tend to loosen easily, so
,047 in.)> (.I 18 in.)> 18A0766 apply manual pressure again.
BODY - Sunroof 2397
SUNROOF N22TTBAD
-- REMOVAL AND INSTALLATION
demoval steps
1. Sunshade
2. Roof lid glass or deflector
3. Weatherstrip
+w ++ 4. Headlining
5. Base plate assembly
6. Hinge female assembly
+* 7. Splash shield NOTE
(I 1 Reverse the removal procedures to reinstall.
Quarter trim (Refer to P.23-85.) (2) ** : Refer to “Service Points of Removal”.
Center pillar trim (Refer to P.23-85.) (3) l * : Refer to “Service Points of Installation”.
l ++ 8. Drain hose (4) m : Non-reusable parts.

4. REMOVAL OF HEADLINING
Refer to P.23-89.
8. REMOVAL OF DRAIN HOSE
Tie a cord at the end of the drain hose and pull out the drain
hose toward the vehicle interior.
23-78 BODY - Sunroof

8. INSTALLATION OF DRAIN HOSE AZ
(I) Tie the,cord (passed through at the time of removal) to . .i
the end of the drain hose.
(2) Pull the cord and pass t’he drain hose through.
(3) Install the grommet at the front side, and install so that
the amount of projection of the drain hose is as shown
in the figure.
25-35 mm
7. INSTALLATION OF SPLASH SHIELD

Refer to P.23-51.
4. INSTALLATION OF HEADLINING
Refer to P.23-89.
23-78 BODY - Instrument Panel 23-79
INSTRUMENT PANEL NZBUAAP
I_- For installation of the instrument panel, the bolts and screws described below are used. They are indicated
by symbols in the illustration.
Symbo Part name and shape Size mm (in.) ;ymbo Part name and shape Size mm (in.)
Tapping screw D-5 t.20) Washer assembled D-8 l.31)

(Black) L-20 f.79) L-25 t.98)
H
lOUO42(
Tapping screw D-5 1.20) Washer assembled D-6 t.24)

L-25 t.98) bolt L- 16 (.63)
I
19A0274
Tapping screw D-4 t.16) Washer assembled D-6 f.24)

L-10 r.391 bolt L-16 l.63)
J
19K653 lSW65!
Tapping screw D-5 f.20) Tapping screw D-5 (.20)

L-16 l.63) L- 16 i.631
K
653
Washer assembled D-6 t.24) Machine screw D-4 t.16)

screw (Black) L-20 l.79) (Black) L-10 l.39)
E L
18110419
Washer assembled D-5 t.20) ~a2h$e screw D-4 (.‘16)

screw ! Black) L-20 t.791 L-10 t.391
F M
18UO419 WA0275
Nasher assembled I-6 t.24) \Nasher assembled D-5 t.20)

3olt -=- 16 i.63) Iicrew L-16 l.63)
G N
8UO420 19A0165
1rapping screw D-5 l.20)

D - Thread diameter L-12 t.471
L = Effective thread length
0
18UO418
-I-
23-80 BODY - Instrument Panel
REMOVAL AND INSTALLATION - ?7
Nm
6-9 ft.lk.
15. Combination meter

Removal steps 16. Speedometer cable adapter
1. Plug 17. Speaker garnishes
2. Knee protecter assembly 18. Bracket
3. Hood lock release handle 19. Heater control assembly installation
4. Column cover lower screws
5. Column cover upper 20. Lap cooler duct
6. Cover (A) 21. Shower duct (L.H.1
7. Cluster panel assembly (A) 22. Steering shaft mounting bolt(s)
8. Radio panel 23. Instrument panel mounting screws
9. Radio or radio and tape player 24. Instrument panel mounting bolts
10. Center air outlet assembly 25. Instrument panel assembly
11. Dial knob (A)
12. Cluster panel assembly (B) NOTE
13. Stopper (1) Reverse the removal procedures to reinstall.
14. Glove box assembly (2) l * : Refer to “Service Points of Removal”
BODY - Instrument Panel 23-81
SECT. A-A SERVICE POINTS OF REMOVAL
10. REMOVAL OF CENTER AIR OUTLET ASSEMBLY
Removing the paw1 of the center air outlet assembly with a
flat-tip ( - 1 screwdriver, remove the center air outlet
assembly with the plastic trim tool.
Flat-tip ( - ) screwdriver
19A0274
1910267
16. REMOVAL OF SPEEDOMETER CABLE ADAPTER

(1) Disconnect the speedometer cable at the transaxle end
of the cable.
(2) Pull the speedometer cable slightly toward the vehicle
interior, release the lock by turning the adapter to the left
or right, and then remove the adapter.
23-82 BODY - Instrument Panel
9N
23
Cluster panel (A) disassembly steps Knee protector disassembly steps

1. Switch holder (A) 12. Lap cooler grill assembly
2. Headlight pop-up switch 13. Knee protector
3. Plug (A)
4. Rheostat Glove box disassembly steps
5. Cluster panel (A) 14. Glove box lock assembly
15. Glove box pad
Cluster panel (B) disassembly steps
16. Glove box hinge
6. Switch holder (5) 17. Glove box
7. Hazard switch
8. p;Fr window defogger switch or plug Instrument panel disassembly steps
18. Glove box light switch
9. $far wiper and washer switch or plug 19. Lower frame
20. Corner pad
10. Heater control panel assembly 21. Glove box striker
II. Cluster panel (B) 22. Glove box light bracket
23. Speakers
BODY - Instrument Panel 23-83
1910260
24. Air duct (A) 33. Instrument panel wiring harness

25. Air duct (B) 34. Instrument panel pad
26. Distribution duct 35. Vin plate
27. Side defroster hoses 36. Instrument panel
28. Defroster nozzle assembly
29. Side defroster grilles
30. Side air outlet assembly
31. Bracket NOTE
32. Combination meter wiring harness (I) Reverse the disassembly procedures to reassemble
connector connections (2) 4, : Refer to “Service Points of Disassembly”.

32. DISCONNECTION OF COMBINATION METER WIRING
HARNESS CONNECTORS
Insert a flat-tip I- 1 screwdriver and open the tab of the
connector, and then remove the harness connectors.
23-84 BODY - Floor Console
N23lJBAP
FLOOR CONSOLE
REMOVAL AND INSTALLATION Gk2 /---I
Removal stew
1 Plug
2. Side cover (A)
3. Side cover (B)
4. Cover (6) 11' ld 19102e1)
5. Manual transaxle shift lever knob
6. Cup holder 10. Guide ring <Vehicles for U.S.>
7. Carpet 11. Shoulder belt <Vehicles for U.S. >
8. fCor;e~tion for floor console wiring 12. Floor console assembly
9. POWER (PWR)/ECONOMY (EC01 NOTE

changeover switch connector <A/T> Reverse the removal procedures to reinstall.
16
Disassembly steps
1. Hinge
2. Stoooers
3. Lid ‘inneF
4. Lock lever 19AO414
5. Lock lever spring
6. Accessory box lid 14. Ashtray
7. Floor console garnish assembly 15. Ashtray spring
8. Floor console wiring harness 16. Cigarette lighter
9. Coin box 17. Plug
10. POWER (PWR)/ECONOMY (ECO) 18. Side cover (C)
changeover switch < AIT > 19. Console cover <Vehicles for Canada >
11. Coin holder < M/T> 20. Floor console
12. Shift lever boot <M/T> NOTE
13. Panel <A/T> Reverse the disassembly procedures to reassemble.
BODY - Trims 23-85
TRIMS
‘A REMOVAL AND INSTALLATION
6,
35-65 Nm
25-40 ftlbs.
19AO413
Cowl side trim removal steps Rear side trim removal steps
1. Scuff plate Rear seat (Refer to P.2393.1
2. Cowl side trim 1. Scuff plate
Quarter trim removal steps 3. Center shelf
4. Shelf holder
Rear seat (Refer to P.23-93. 4* 5. Quarter trim
1. Scuff plate 7. _ tB)-
-. Lid
a* 5. Quarter trim 8. Lid (D)
6. Quarter trim lower bracket l * 9. Rear end trim
Center shelf removal steps 13. Rear seat belt anchor plate
14. Retractor cover
3. Center shelf 15. Rear seat belt protector
4. Shelf holder a* 16. Rear side trim
Rear end trim removal steps 17. Shelf catcher
18. Rear speaker bracket assembly
7. Lid (B) 1 S.‘Quarter trim upper bracket
8. Lid (D)
4* 9. Rear end trim NOTE
For the bolts indicated by the h. screws are
10. Bracket used for the left side.
11. FWD bracket <FWD>
12. AWD trim bracket <AWD>
23-86 BODY - Trims
<Vehicles for U.S.>
-55 Nm
Qi----- %40 ft.lbs.
19AO412
<Vehicles without rear air spoiler > <Vehicles with rear air spoiler >
u.u 19AO300
19AO301
Center pillar trim and front pillar trim removal Rear pillar trim removal steps
steps Rear seat (Refer to P.23-93.)
Rear seat (Refer to P.23-93.) 1 Scuff plate
1 Scuff plate 4* 5. Quarter trim
5. Quarter trim 20. Coat hanger
40
4* 23. Center pillar trim
4, 21. Sash guide cover <Vehicles for
4* 28. Rear pillar trim
Canada >
22. Front seat belt sash guide <Vehicles for Liftgate trim and flange trim removal steps
Canada > 29. High mounted stop light cover
20. Coat hanger 30. Liftgate trim
4*
4, 23. Center pillar trim 31. Flange trim
c* 24. Front pillar trim
Front belt rail trim and rear belt rail trim removal NOTE
steps (1) Reverse the removal procedures to reinstall,.,
(2) 4, : Refer to “Service Points of pemoval
Rear seat (Refer to P.23-93.) (3) The l symbol indicates the trim clip.
1 Scuff plate (Refer to P.23-87.)
4* 5. Quarter trim
20. Coat hanger
4, 23. Center pillar trim
4* 24. Front pillar trim
4* 25. Guide rail <Vehicles for U.S.>
26. Rear belt rail trim <Vehicles for U.S.>
27. Front belt rail trim <Vehicles for U.S.>
BODY - Trims 23-87
TRIM CLIP REMOVAL/INSTALLATION PROCE-
DURES
The type of clip shown in the illustration, which is used for
the installation of. instrument panel, should be removed and
installed by the following procedures described below.
1@Poo70
REMOVAL
(1) Use a cross-tip (+) screwdriver to push inward the pin (at
the centre of the trim clip) to a depth of about 2 mm
(.08 in.).
(2) Pull the trim clip outward to remove it.
Caution
Do not push the pin inward more than necessary
because it may damage the grommet, or the pin may
fall in, if pushed too far.
10P0081
INSTALLATION
(1) With the pin pulled out, insert the trim clip into the hole
Trim in the trim.
(2) Push the pin inward until the pin’s head is flush with the
grommet.
(3) Check whether the trim is secure.
Gro
19P0000

5. REMOVAL OF QUARTER TRIM
(1) Remove the quarter trim mounting screws and trim clip.
(2) Using the plastic trim tool, remove the clip mounting area
on the back of the quarter trim, and remove the quarter
trim.
9. REMOVAL OF REAR END TRIM

(1) Remove the rear end trim mounting screws and clips.
(2) Using the plastic trim tool, remove the clip mounting area
on the back of the rear end trim, and remove the rear
end trim.
23-88 BODY - Trims
16. REMOVAL OF REAR SIDE TRIM

(1) Remove the cargo room light on the rear side trim LH.).
(2) Remove the rear side trim mounting screws and clips.
(3) Slowly pulling the rear side trim toward you, remove the
clip mounting area on the back of the rear side trim, and
remove the rear side trim.
21. REMOVAL OF SASH GUIDE COVER
Refer to P.23-98.
Vehicles for U.S. Vehicles for Canada 23.REMOVAL OF CENTER PILLAR TRIM
Using the plastic trim tool, remove the clip mounting areas
on the back of the center pillar trim, and remove the center
pillar trim.
24.REMOVAL OF FRONT PILLAR TRIM

and Velcro areas <Vehicles for U.S. > on the back of the
front pillar trim, and remove the front pillar trim.
25.REMOVAL OF GUIDE RAIL
Refer to P.23-94.
I I /I lQA028!
Vehicles for Ca
28.REMOVAL OF REAR PILLAR TRIM

on the back of the rear pillar trim, and remove the rear pillar
trim.
BODY - Trims/Headlining 23-89
3O.REMOVAL OF LIFTGATE TRIM
on the back of the liftgate, and remove the liftgate.
HEADLINING N23UDAX
PEMOVAL AND INSTALLATION

Pm-removal Operation
l Removal of Center Pillar Trim
(Refer to P.23-85.)
l Removal of Front Pillar Trim
(Refer to P.23-85.)
l Removal of Guide Rail
(Refer to P.23-94.)
0 Installation of Guide Rail
(Refer to P.23-94.)
l Installation of Front Pillar Trim
(Refer to P.23-85.)
l Installation of Center Pillar Trim
(Refer to P.23-85.)
19A0314
Vehicles without sunroof Vehicles with sunroof
Removal steps
1. Dome light
2. Sunvisor
3. Sunshade
4. Roof lid glass
4* 5. Headlining trim
6, Sunmf headlining trim
7. CYlps NOTE
(I l Reverse the removal procedures to reinsta\\;,
8. Headlining (2) +e : Refer to “Service Points of Removal
9. Trim retainer
23-90 BODY - Headlining/Front Seat

5. REMOVAL OF HEADLINING TRIM
Remove the headlining trim like turning it outward.
19A0294
FRONT SEAT NZBUEAP
17-26
12-19
17-26 ft.lbs. WA0306
Removal steps 7. Lap belt <Vehicles for U.S.>

l + 1. Slider rail anchor cover 8. Guide ring <Vehicles for U.S.>
l + 2. Seat anchor covers 9. Shoulder belt <Vehicles for U.S.>
3. Slider rail 10. Front seat assembly
l * 4. Seat mounting bolts
l * 5. Seat mounting nuts NOTE
6. Seat belt switch connector (1) Reverse the removal procedures to reinstall.
(L.H. only) (2) +* : Refer to “Service Points of Installation”.
BODY - Front Seat 23-91
5. INSTALLATION OF SEAT MOUNTING NUTW4. SEAT
Bolts
MOUNTING BOLTS
After checking that the seat adjuster is locked at both sides,
provisionally tighten (in the A,B,C and D sequence) the seat
mounting nuts and the seat mounting bolts; then fully tighten
at the specified torque.
19AO308
Front Front seat forward 2. INSTALLATION OF SEAT ANCHOR COVERS

installation bracket
(1) Securely install the front side seat.anchor forward tab to
the front seat forward installation bracket.
(21 Turn the seat anchor cover in the direction indicated by
the arrow, and install the tab at the side part to the hole
in the bracket side part.
(3) Securely install the rear side seat anchor cover rearward
tab to the front seat rearward installation bracket.
(4) Turn the seat anchor cover in the direction indicated by
A-A cross-section
the arrow and insert the side tabs into the holes in the
Forward tab front seat rearward installation bracket side part.
. Front seat’s rear
)\& area mounting
z-2 bracket
L anchor \
1
cover Forward tab
B-B cross-section 19A0124
-
1. INSTALLATION OF SLIDER RAIL ANCHOR COVERS
Securely the rear pawl of the slider rail anchor cover to the
mounting bracket on the rear of the slider rail, and mount the
slider rail anchor cover, turning its front area.
Slid; rail Slide kail’s rear

area mounting
bracket WA0302
23-92 BODY - Front Seat
35-55 Nm
25-40 ft.lbs. ---.-.,
9-14 Nm 6
7-10 ft.lbs. /
e 7-10 ft.lbs.
19Ao3m
35-55 Nm
25-40 ft.lbs.
r I
9-14 Nm
7-10 ft.lbs. 4
k 9-14 Nm \ 3 5 - 5 5 N m 18A0720
7-10 ft.lbs. 25-40 ft.lbs.
13. Buckle
Disassembly steps 14. Slider bracket cover
1. Reclining knob 15. Slider bracket
2. Belt holder <Vehicles for U.S. > 16. Seat frame protector
3. Shield cover 17. Bushing
4. Thigh support cap 18. Seat adjuster, inner
5. Thigh support lever 19. Pull wire
6. Thigh support lever garnish 4 $I: ,“S;; ;zt;E;, outer
7. Lumber support cap
8. Side support lever 22. Seatback
9. Lumber support lever
IO. Lumber support lever garnish
11. Guide ring bracket <Vehicles for U.S. > NOTE
12. Buckle cover Reverse the disassembly procedures to reassemble.
BODY - Rear Seat 23-93
REAR SEAT N23UFAN
.~x REMOVAL AND INSTALLATION 4-6 Nm

3-4 ft.lbs.
12-19 ft.lbs.
12-19 ft.lbs.
19AO411
Removal steps
w w 1. Seat cushion NOTE
2. Clips (1) Reverse the removal procedures to reinstall.
3. Seatback (2) +* : Refer to “Service Points of Removal”.
4. Striker (3) l 4 : Refer to “Service Points of Installation”.

1. REMOVAL OF SEAT CUSHION
Pulling the lever, raise the front of the seat cushion and
remove the seat cushion.
I Seat back hinge bracket I SERVICE POINTS OF INSTALLATION

1. INSTALLATION OF SEAT CUSHION
(1) Securely insert the attachment wire of the rear cushion
into under the hinge bracket of the seat back.
(2) Pass the rear seat belt buckle.
(3) Securely insert the hook of the seat cushion into the seat
support bracket.
Seat
bracket 1910323
23-94 BODY - Seat Belt
SEAT BELT N23UQBF

<Front Seat Belt for U.S.-Automatic Seat Belt>
//
35-55 N m
25-40 ft.lbs.
U/16 in. x 25 mm
bolts) ,
n (8 x 20 mm bolts) 25-4.0 ft.lbs.
Driving device assembly removal steps w 14. Front seat assembly

15. Guide ring bracket
Scuff plate (Refer to P.23-85.1 16. Buckle cover
Quarter trim (Refer to P.23-85.)
Center pillar trim (Refer to P.23-86.) 17. Buckle
18. Belt holder
Front pillar trim (Refer to P.23-86.)
1. Automatic seat belt wiring harness Door latch switch removal
connector connection l * 19. Door latch switch
2. Outer casinq mounting screws
3. Motor mouriting bolts- Automatic seat belt control unit removal steps
4. Guide rail mounting bolts (A) Scuff plate (Refer to P.23-85.)
5. Guide rail mounting bolt (B) Quarter trim (Refer to P.23-85.)
6. Guide rail mounting bolts (Cl 20. Automatic seat belt control unit
7. Driving device assembly connector connection
Lap belt removal steps 21. Automatic seat belt control unit
Scuff plate (Refer to P.23-85.) NOTE
Quarter trim (Refer to P.23-85 (1) Reverse the removal procedures to reinstall.
8. Bezzel (2) l * : Refer to “Service Points of Removal”
9. Retractor (for lap belt)
Buckle and belt holder removal steps
10. Guide ring
1 1. Shoulder belt
l * 12. Floor console assembly
13. Seat belt switch connector connection
(L.H. only)
BODY - Seat Belt 23-95
17-26 Nm
35-55 Nm
25-40 ft.lbs.\
19A0309
Shoulder belt removal steps Buzzer removal steps

10. Guide ring Instrument panel assembly
1 1. Shoulder belt 24 (gy;ZfieerrtO P.23-80.)
c* 12. Floor console assembly
22. Outer switch connector connection
23. Retractor assembly (for shoulder belt) NOTE
(2) +e : Refer to “Service Points of Removal”

12. REMOVAL OF FLOOR CONSOLE ASSEMBLY
Refer to P.23-84.
14. REMOVAL OF FRONT SEAT ASSEMBLY
Refer to P.23-90.
19. REMOVAL OF DOOR LATCH SWITCH
Refer to P.23-69.
INSPECTION
MOTOR
(1) Unplug the automatic seat belt motor relay connector.
(2) Connect the terminals (indicated in the illustration) of the
automatic seat belt wiring harness connector directly to the
battery, and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates
smoothly in the reverse direction.
19A0319
RELEASE SWITCH AND FASTEN SWITCH
(1) Remove the release switch and fasten switch.
(2) Connect the tester to the terminals (see the illustration) on *
the automatic seat belt wiring harness connector located on -’
the motor.
Q ET 19A0316 (3) Check the continuity between the terminals.
I) : Terminal to check 1 Release switch 1 Fasten switch 1

the release switch
I+ : Terminal to check 2 4 6
the fasten switch
Release the switch knob 0 0 0 0
Push the switch knob

NOTE
lQA0316
DOOR LATCH SWITCH

Refer to P.23-70.
AUTOMATIC SEAT BELT MOTOR RELAY

(1) Remove the automatic seat belt motor relay.
(2) Check for continuity between terminals under the conditions
described below.
m-al
II
Batterv voltaae
Termi, lal
1 2 3 4 5 6 7
n 0
Continuity no voltage 0 ”
0
16A07.51
I
I
Continuity with voltage
I I I I I I I
NOTE
(1) O-O indicates that there is continuity between the terminals.
(2) O---O indicates terminals to which battery voltage is applied.
19PO363
OUTER SWITCH
(1) Disconnect the outer switch connector.
(2) Pull out the shoulder belt farther than its midpoint and check
the continuity between the terminals.
4 : Terminal to check
outer switch IL.H.1 lQPO361
When the belt is pulled out farther than 0 0
+ : Terminal to check approx. the midpoint
outer switch (R.H.1
When the belt is not pulled out as far as
approx. the midpoint
NOTE
(1) The above inspection permits verification that the outer
switch turns on when the shoulder belt is properly
engaged with the slide anchor. The “midpoint” in the
above procedure refers to the center of the belt length
between the retractor and slide anchor.
(2) O-O indicates that there is continuity between the
terminals.
19A0322
BUCKLE SWITCH
(1) Disconnect the buckle switch connector (L.H. only).
(2) Check the continuity between the terminals.
)I
NOTE
lQA0317 O-O indicates that there is continuity between the terminal.
BUZZER
Check that buzzer sounds when battery voltage is applied to the
buzzer terminal.
i
<Front Seat Belt for Canada>
0 Removal of Front Seat
(Refer to P.23-90.)
0 Removal of Quarter Trim
(Refer to P.23-85.)
l Installation of Quarter Trim
(Refer to P.23-85.)
l Installation of Front Seat
(Refer to P.23-90.)
\ s-55 Nm
9-14 Nm 25-40 ft.lbs.
7-10 ft.lbs.
Buckle removal steps

1. Seat belt switch harness
2. Buckle cover
3. Buckle
Front seat belt removal steps
4. Bolt cap
5. Slide bar
l + 6. Sash guide cover
l + 7. Front seat belt
8. Cover plate
Buzzer removal steps NOTE
Instrument panel assembly (2) +e : Refer to “Service Points of Removal”.
(Refer to P.23-80.) (3) l + : Refer to “Service Points of Installation”
9. Buzzer (4) m : Non-reusable parts

6. REMOVAL OF SASH GUIDE COVER
Insert a plastic trim tool from the lower part and open the
sash guide cover.
INSPECTION
SEAT BELT TIMER
Remove the seat belt timer from the relay box (indoor).
TIMER OPERATION CHECK

(I 1 Connect the battery and the test bulb to the timer, as shown
in the illustration.
(2) Make sure that when terminal 2 is connected to the positive
(+) terminal of the battery, test bulbs 1 and 2 are lighted
for approx. 6 seconds.
19AO239
(3) Make sure that even when terminal 3 is disconnect while test
bulbs 1 and 2 and lighted in (2) above, test bulb 1 remains
lighted.
I ITest b u l b 2 I
t I I
BUCKLE SWITCH
Refer to P.23-97.
BUZZER
R e f e r t o P.23-97.

7. INSTALLATION OF FRONT SEAT BELT
Fit the retractor retaining lug in the slot provided in the
vehicle body, and secure the retractor with the bolt by
tightening it to the specified torque.
<Rear Seat Belt>
35-55 Nm
25-40 ft.lbs.
Inner seat belt removal steps 3 19A029S
M l 1. Rear seat cushion

2. Inner seat belt 7. Seat belt protector
3. Bracket 8. Retractor bracket mounting bolts
9. Outer seat belt
Outer seat belt removal steps
w H 1. Rear seat cushion NOTE
l + 4. Seat belt anchor plate attaching bolts (I 1 Reverse the removal procedures to reinstall.
5. Retractor cover (2) ** : Refer to “Service Points of Removql”.
*I) 6. Rear side trim (3) l + : Refer to “Service Points of Installation”.

1. REMOVAL OF REAR SEAT CUSHION
Refer to P.23-93.
6. REMOVAL OF REAR SIDE TRIM
Refer to P.23-85.

4. INSTALLATION OF SEAT BELT ANCHOR PLATE AT-
TACHING BOLTS
Install the anchor plate so that it conforms to the floor bead.
1. INSTALLATION OF REAR SEAT CUSHION
Refer to P.23-93.
24-l
HEATERS AND
AIR CONDITIONING
CONTENTS N24M--
AIR CONDITIONER SWITCH .......................... 30 Idle-up Operation Check .............................. 25

Manifold Gauge Set Installation .................. 11
BLOWER ASSEMBLY ..................................... 33
Performance Test ......................................... 16
COMPRESSOR ................................................. 37 Power Relay Check ...................................... 24
Refrigerant Leak Repair Procedure ............. 17
CONDENSER AND CONDENSER FAN
MOTOR ............................................................ 45 Testing System for Leaks ........................... 15
Test Procedures ........................................... 11
ENGINE COOLANT TEMPERATURE
-‘-., SWITCH ............................................................ 51 SPECIFICATIONS ......... . ................................... 2
EVAPORATOR ................................................. 34
Lubricants ...................................................... 3
HEATER CONTROL ASSEMBLY .................... 26 Sealant and Adhesives ................................. 3
HEATER UNIT ................................................. 31
REFRIGERANT LINE ........................................ 47
TROUBLESHOOTING . . . ..a................................ 3
RESISTOR ........................................................ 29
VENTILATORS
SAFETY PRECAUTIONS ................................. 10 (AIR INLET AND AIR OUTLET) ..,....s............. 50
SERVICE ADJUSTMENT PROCEDURES.. ..... VENTILATORS

11 49
(INSTRUMENT PANEL) ..,...................*...........
Compressor Drive Belt Adjustment ............. 23
Compressor Noise ........................................ 24
Handling Tubing and Fittings ....................... 22
24-2 HEATERS AND AIR CONDITIONING - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS N24cA- -
Heater unit
Type Three-way-flow full-air-mix system
Heater control switch Dial type
Compressor
Model lOPA
Refrigerant unit lubricant cc (cu.in.1 DENS0 OIL 6 or SUNISO 5GS 80f20 (4.9&l .2)
V belt size mm (in.) <1.8L Engine> 920 (36.2) <2.0L DOHC Engine> 940 (37.0)
Dual pressure switch
High pressure switch kPa (psi) OFF: 2,700 (384) ON: 2,100 (299)
Low pressure switch kPa (psi) OFF: 210 (30) ON: 235 (33)
Freezer prevention “C (“F) Air temperature thermostat
OFF: 3 (37.4) ON: 4 (39.2)
Refrigerant and quantity g bd R-12 MAX 935 (33)
SERVICE SPECIFICATIONS N24CB.-
Standard value
k
Air therm0 sensor and air inlet sensor standard
- /.
resistance value n
0°C (32°F) 4,852f243
15°C (59°F) 2,341 f234
25°C 177°F) 1,500f 150
Engine coolant temperature switch
Switch-OFF temperature “C (“F) 1 1 2 - 1 1 8 (233-244)
Amount of V belt deflection mm (in.)
When new belt installed 4 - 5 (.16-.2)
When used belt installed 5.5-6 (.22-.24)
Amount of V-ribbed belt deflection mm (in.)
When new belt installed 4 . 5 - 5 (.18-.2)
When used belt installed 5 . 5 - 6 (.22-.24)
Clutch clearance m m ( i n . ) 0.35-0.65 (.014-,026)
Condenser fan motor resistor resistance value 52 0.26-0.32
TORQUE SPECIFICATIONS N24CC-
Items Nm ft.lbs.
Front housing installation bolt 24-28 18-21
Compressor bracket tightening bolt 45-55 33-39
Compressor tightening bolt 23-27 17-19
Tension pulley center nut (bolt) 32-48 24-36
Dual pressure switch 9-11 7-8
Engine coolant temperature switch 30-40 22-28
HEATERS AND AIR CONDITIONING - Specifications/Troubleshooting 24-3
LUBRICANTS u24as-
;xi Quantity
Items Specified lubricants
Each connection of refrigerant line DENS0 OIL 6 or SUNISO 5GS As required

Shaft seal of the compressor
SEALANT AND ADHESIVES N24CE-
, Items Specified sealant and adhesive
Engine coolant temperature switch threaded part MOPAR Part No.4318034 or equivalent
TROUBLESHOOTING N24EBAQ
Heater insufficient heat Obstructed heater outlets Correct

Blend air dampers improperly adjusted or binding
Thermostat malfunction Replace

Obstructed heater hoses
Improperly adjusted control cables Adjust
Plugged or partially plugged heater core Clean or replace
No ventilation even when Incorrect adjustment of mode selection dampers Adjust

mode selection knob is Incorrect installation of mode selection control wire
operated
Ducts are incorrectly/incompletely connected, crushed, Repair or replace
bent or clogged.
Blower motor inoperative Poor grounding Correct
Burnt-out fuse Replace

Malfunction blower switch
Malfunction resister
Malfunction blower motor
Malfunction heater relay
24-4 HEATERS AND AIR CONDITIONING - Troubleshooting
TROUBLESHOOTING QUICK-REFERENCE TABLE
Compressor doesn’t operate.
Air conditioner switch: ON
1
Can the activation sound of the Yes The compressor magnetic clutch
magnet clutch be heard when - is normal. The compressor body is
battery voltage is applied to the air abnormal.
conditioner compressor magnet
clutch?
Is the voltage Bv between ground Malfunction of the air conditioner Refer to P.24-6.
and terminal (4) of the air switch.
conditioner switch equivalent to
battery voltage when’the air
conditioner switch is pressed in
one step?
Is the voltage Bv between ground
and terminal (2) of the air
conditioner switch equivalent to
L batten/ voltage when the air

conditioner switch is pressed in
two steps?
Yes
1
Is there continuity between r \lo Malfunction of the magnetic
terminals (2) and (4) of the clutch relay.
magnetic clutch relay?
i terminals (1) and (3) when Bv is

applied between terminals (2) and
(4)?
Yes
Is the high-pressure side ! Gas leakage or excess refrigerant.
refrigerant pressure within the
range of 21 O-2,700 kPa (29.9-
384 psi) when a gauge manifold
I is connected to the service valve

and the high-pressure side
refrigerant pressure is measured?
/Yes
Is there continuity between the No_ Malfunction of the dual-pressure
dual-pressure switch terminals? switch.
Yes
Continue to next page.
HEATERS AND AIR CONDITIONING - Troubleshooting 24-5
From previoys page.
I
When the resistance of the air- N o Malfunction of tha air-therm0 Refer to P.24-6.
-
therm0 sensor is measured sensor.
[with the air conditioner switch
OFF and when the ambient
temperature of the air-therm0
sensor is 25°C (77“F)], is the
measured resistance approx.
1.5f0.15 kP?
1Yes
When the resistance of the air- Refer to P.24-6.
inlet sensor is measured [with the
air conditioner switch OFF and
when the ambient temperature of
the air-inlet sensor is 25°C (77”F)l
is the measured resistance
approx. 1.5f0.15 k&2?
I
1 Yes
Does idle-up occur immediately No Malfunction of the DC motor
after the air conditioner switch is cl800 Engine>
switched ON? Malfunction of the stepper motor
~2000 DOHC Engine>
Yes Malfunction of the MPI control unit
* Malfunction of the air conditioner Refer to P.24-6.

control unit.
AIR CONDITIONER CONTROL Description of Operation
UNIT CIRCUIT (1) A negative-characteristic thermistor is employed
for the air-therm0 sensor and the air-inlet sensor
in order to convert the ambient temperature at
the sensor part to resistance.
1 Battery I
The sensor power-supply voltage (5V) of the air
conditioner control unit is applied to each sen-
sor.
Blower switch (2) The compressor operation mode changes (from

lital OFF to ECONO to A/C...) each time the air
conditioner switch is pressed. When the air
Air conditioner conditioner switch is pressed in to the first step,
the mode is changed to the ECONO mode (the
indicator illuminates in orange, and the voltage
at terminal 4 of the air conditioner switch
becomes Bv.
When pressed in to the second step, the mode
is changed to the air conditioner mode (the
indicator illuminates in green), and the voltage at
terminal 2 of the air conditioner switch becomes
Bv.
Bv: Battery voltage
I
1-i
Air inlet Air outlet
sensor sensor
temperature (3) The output (terminal 4) of the air conditioner

Corn- L T control unit is output when all of the following
pressor
relay I I
conditions are satisfied.
*Wire harness side @ The air conditioner switch is ON (ECONO or
A/C mode).
Magnetic A
MPI control @ The air-therm0 sensor ambient temperature
clutch (evaporator outlet air temperature) is 4°C
(39°F) or higher.
@ The air-inlet sensor ambient temperature
(evaporator intake air temperature) is 4°C
(39°F) or higher.
HEATERS AND AIR CONDITIONING - Troubleshootinq
’ Wire harness side TROUBLESHOOTING HINTS

-. Inspection of Air Conditioner Control Unit
Disconnect the amplifier and inspect the connector on the wire
harness side as shown in the chart below.
Test Conditions:
(1) Ignition switch: ON
(2) Air conditioner switch: ON
(3) Temoerature control lever: MAX COOL
2OAO405 (4j Bloier switch: HI
Terminal Measurement item Tester connection Conditions Specified value

1 Resistance l-6 - 1,500f150 sz ’
at 25°C (77°F)
2 Voltage 2-3 Airtcchonditioner System voltage
2-8
o v
Continuity 3-Ground Continuity
Continuity 4-Ground Continuity
Resistance 5-7 - 1,500+ 150 s-2
at 25°C (77’F)
I I
Continuity 8-Ground - Continuity

Voltage 9-3 Therm0 sensor OFF System voltage
9-8 78°C (172°F)
ov
:5k (185°F)
10 Voltage 10-3 ECONO switch System? voltage

10-8
o v
If the connector on the wire harness side is correct, replace the air conditioner control unit.
IARNESSES AND COMPONENTS LAYOUT DIAGRAM
<Dash panel>
36AOO51
1. Air conditioner switch
2. Air conditioner control unit
3. Air-inlet sensor
4. Air-therm0 sensor
Air conditioner control unit D Condenser fan motor relay C
Air conditioner switch G Dual pressure switch B
Engine coolant temperature switch A

Air inlet sensor F <2.0L DOHC Engine>
Air therm0 sensor F Heater relay H
Blower motor High relay E Magnetic clutch relay C
rrIor:enser fan motor High-Low selecting C

I
NOTE
The “Name” column is arranged in alphabetical order.
q \
q ---
HEATERS AND AIR CONDITIONING - Troubleshooting 24-9
Blower motor High relay

24-10 HEATERS AND AIR CONDITIONING - Safety Precautions
SAFETY PRECAUTIONS N24PAAD
The refrigerant used in all air conditioner is R-l 2. It is Caution ‘irr

transparent and colorless in both the liquid and Always work in a well-ventilated room.
vapor state. Since it has a boiling point of -29.8”C Good ventilation is vital in the working area. Always
(-85.6”F). at atmospheric pressure, it will be a vapor discharge the refrigerant into the service bay ex-
at all normal temperatures and pressures. The vapor haust system or outside the building. Large quanti-
is heavier than air, non-flammable, and nonexplo- ties of refrigerant vapor in a small, poorly ventilated
sive. It is nonpoisonous except when it is in direct room can displace the air and cause suffocation.
contact with open flame. It ia noncorrosive except Although R-12 vapor is normally nonpoisonous,
when combined with water. The following precau- contact with an open flame can cause the vapor to
tions must be observed when handling R-12. become very poisonous. Do not discharge large
Caution quantities of refrigerant in an area having an open
Wear safety goggles when servicing the refriger- flame. A poisonous gas is produced when using the
ation system. flame-type leak detector. Avoid inhaling the fumes
R-12 evaporates so rapidly at normal atmospheric from the leak detector.
pressures and temperatures that it tends to freeze Caution
anything it contacts. For this reason, extreme care Do not allow liquid refrigerant to touch bright
must be taken to prevent any liquid refrigerant from metal.
contacting the skin and especially the eyes. Always Refrigerant will tarnish bright metal and chrome
wear safety goggles when servicing the refrigera- surfaces, and in combination with moisture can
tion part of the air conditioning system. Keep a severely corrode all metal surfaces.
bottle of sterile mineral oil handy when working on
the refrigeration system. Should any liquid re- R-12 Refrigerant Bundling
frigerant get into the eyes, use a few drops of Refrigerant Recycling
mineral oil to wash them out. R-12 is rapidly R-12 refrigerant is a chloro-floro-carbon (CFC) that
absorbed by the oil. Next splash the eyes with can contribute to the depletion of the ozone layer in
plenty of cold water. Call your doctor immediately the upper atmosphere. A
even though irritation has ceased after treatment. Ozone filters out harmful radiation from the sun. - -/.
Caution To assist in protecting the ozone layer, Mitsubishi
Do not heat R-12 above 40°C (104°F). Motors Corporation recomends that a R-12 re-
frigerant recycling device that meets SAE standard
In most instances, moderate heat is required to J1991 be used.
bring the pressure of the refrigerant in its container Contact an automotive service equipment supplier
above the pressure of the system when charging or for refrigerant recycling equipment that is available
adding refrigerant. A bucket or large pan of hot in your area.
water not over 40°C (104°F) is all the heat required Refer to the operating instructions provided with the
for this purpose. Do not heat the refrigerant contain- recycling equipment for proper operation.
er with a blow torch or any other means that would
raise temperature and pressure above this tempera-
ture. Do not weld or steam clean on or near the
system components or refrigerant lines.
Caution
Keep R-12 containers upright when charging the
system.
When metering R-12 into the refrigeration system,
keep the supply tank or cans in an upright position. If
the refrigerant container is on its side or upside
down, liquid refrigerant will enter the system and
damage the compressor.
HEATERS AND AIR CONDITIONING - Service Adjustment Procedures 24-I 1
MANIFOLD GAUGE SET INSTALLATION N24FDAF
Suction
gauge
Discharge
hose
7 Discharge
Port 20A0460
Manifold Gauge Valves-should be closed when connecting the manifold gauge set to the service port of
the compressor and the discharge hose. The suction gauge valve at the left is opened to provide a passage
between the suction gauge and the center manifold outlet. The discharge gauge valve at the right is opened
to provide a passage between the discharge pressure gauge and the center manifold outlet.
Detailed instructions for proper use of the gauge set manifold are contained in the text covering each test and
service operation employing these gauges.
Suction Gauge-the left side of the manifold set is calibrated to register 0 to 100 kPa (0 to 15 psi) and 0 to
1,000 kPa (0 to 145 psi). This gauge is connected to the suction port of the compressor.
Discharged Gauge-the right of the manifold set is calibrated to register 0 to 2,100 kPa (0 to 305 psi). For all
tests this gauge is connected to the discharge port of the system.
Center Manifold Outlet-provides the necessary connection for a long service hose used when discharging
the system, using a vacuum pump to “pull a vacuum” before charging the system, and for connecting the
supply of refrigerant when charging the system.
TEST PROCEDURES N24FEAS
RECEIVER DRIER
To Test the Receiver Drier
(1) Operate the unit and check the piping temperature by
touching the receiver drier outlet and inlet.
(2) If there is a difference in the temperatures, the receiver
drier is restricted.
Replace the receiver drier.
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass is a refrigerant level indicator. To check the
refrigerant level, clean the sight glass and start the vehicle
engine. Push the air conditioner button to operate the
compressor, place the blower switch to high and move the
temperature control lever to max cool. After operating for a few
minutes in this manner, check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is engaged,
the compressor discharge line is warm and the compressor
inlet line is cool; the system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is engaged
and there is no significant temperature difference between
compressor inlet and discharge lines: the system has lost
some refrigerant.
24-12 HEATERS AND AIR CONDITIONING - Service Adjustment Procedures
(3) If the sight glass is clear and the magnetic clutch is
disengaged; the clutch is faulty or, the system is out of
refrigerant. Perform low pressure switch test to determine
condition. Check low pressure switch, and clutch coil for
electrical continuity.
(4) If the sight glass shows foam or bubbles, the system could
be low on charge. Occasional foam or bubbles are normal
when the ambient temperature is above 43°C (110°F) or
below 21°C (70°F).
Adjust the engine speed to 1,500 rpm. Block the air-flow
thru the condenser to increase the compressor discharge
pressure to 1,422 to 1,520 kPa (206 to 220 psi). If sight
glass still shows bubbles or foam, system charge level is
low.
The refrigerant system will not be low on charge unless
there is a leak. Find and repair the leak. If the leak can be
repaired without discharging the system an oil level check
is not necessary. Use the procedure for correcting low
refrigerant level found in the Refrigerant System Service
Procedure Section.
DUAL PRESSURE SWITCH
The dual-pressure switch is a combination of the low-pressure
switch (for checking the quantity of refrigerant) and the,
high-pressure switch (for prevention of overheating); it is
installed on the tube, and, when the pressure becomes
approximately 210 kPa (30 psi) or lower, the compressor stops,
thus preventing the compressor from being damaged by heat.
When the pressure reaches 2,700 kPa (384 psi) or higher, the
------__-- compressor stops, thus preventing overheating. There is
210 235 2,100 P r e s s u r e generally no necessity for inspection; if, however, an unusual
(30) (33) (299) 2& condition, such as non-operation of the compressor is encoun-
tered, check by following the procedures below.
(1) Check for continuity of the dual-pressure switch.
kPa
(psi) 2OPOO14
NOTE
If the air temperature drops to 0°C (32°F) or lower during
cold weather, the air conditioner will not operate (no
continuity).
(2) If there is an insufficient amount of refrigerant, check the
refrigerant amount by looking through the sight glass of the
receiver; supply refrigerant if necessary.
(Refer to P.24-21.)
HEATERS AND AIR CONDITIONING - Service Adjustment Procedures 249*I3
(3) Set the gauge manifold in place and check whether or not
the pressure at the high-pressure side has become the
--
dual-pressure switch activation pressure.
(4) Replace the switch if, under ordinary conditions, there is no
continuity.
Caution
The condition can be considered to be satisfactory if
there is continuity.
Never increase the pressure in a deliberate attempt to
obtain an abnormally high temperature, because to do
so risks blowing the compressor relief valve.
AIR-THERM0 SENSOR AND AIR-INLET SENSOR
If frost forms on the surfaces of the evaporator fins, the cause
might be a malfunction of air-therm0 sensor.
Air-therm0 The temperature of the air-flowing from the evaporator’s outlet
sensor
is sensed by the thermistor, and the signals conveying this data
are input to the air conditioner control unit, thus switching the
compressor’s clutch ON or OFF.
This functions when the evaporator’s air-flow is low, or the
evaporator’s fins are clogged by dust, etc., or when the amount
Air inlet E>aporator
sensor
of refrigerant is insufficient.
These sensors detect the temperature within the passenger
compartment and the temperature at the cooling unit inlet,
thus causing changes of the resistance value, and this data is
provided to the air conditioner control unit as input.
How to Test the Therm0 Sensor and Air-Inlet Sensor
(1) Disconnect the sensor’s connector at the evaporator case,
and by using an ohmmeter, measure the resistance. The
resistance is normal if it is within the range shown in the
figure at the left; if the resistance is not normal, replace.
(2) If the sensor is normal, there is a malfunction of the air
conditioner control unit, and it should be replaced.
Standard value:
Passenger compartment temperature sensor resist-
ance value:
0°C (32°F) 4,852+243 (S-2)
15°C (59°F) 2,341+234 (S-2)
25°C (77°F) 1,500+150 (52)
ENGINE COOLANT TEMPERATURE SWITCH
<2.0L DOHC Engine>
The engine coolant temperature switch is connected in series
with the compressor magnetic clutch power relay.
It disengages the compressor when the temperature of
engine coolant rises above 115°C (239°F).
This is designed to prevent engine overheating when cooling
air is not sufficient for the condenser and radiator. If the engine
coolant temperature switch operates to disengage the com-
pressor, check for the condenser and radiator surface condi-
tions, belt tension and engine coolant level and correct, if
necessary.
MAGNETIC CLUTCH
(I) Disconnect the wiring to the magnetic clutch.
(2) Connect battery (+) voltage directly to the wiring for the ,”
magnetic clutch.
(3) If the magnetic clutch is normal, there will be a “click”. If
the pulley and armature do not make contact (“click”),
there is a malfunction.
Using an ohmmeter, measure the resistance of the clutch

coil between the clutch lead wire and ground.
Standard resistance: 3.4-3.8 Q at 20°C (88°F)
If resistance is not as specified, replace the coil.
COMPRESSOR
-Discharge (1) Install the manifold gauge set, and run the air conditioner.
w-w (2) If a pressure of approx. 490 kPa (71 psi) is indicated on the
suction gauge side and a pressure of approx. 883 kPa (128 ,“s
psi) is indicated on the discharge gauge side, the compres- -I
sor has abnormal compression.
Replace the compressor.
(3) If a pressure of 294 to 392 kPa (43 to 57 psi) is indicated on

Suction Dischal the suction gauge side and a pressure of approx. 1,961 kPa
gauge gauge (284 psi) is indicated on the discharge gauge side, it is
suspected that air is present in the air conditioning system.
Discharge the system, evacuate and recharge with speci-
fied amount of refrigerant.
2OUO306
(4) During operation of the air conditioner, cold air may stop
Suction Discharge flowing after the elapse of time and this state is maintained
gauge gauge before cold air flows out again. If cold air stops flowing out
with negative pressure indicated on the suction gauge side
and a pressure of 588 to 980 kPa (85 to 142 psi) indicated
on the discharge gauge side, it is suspected that water is L=I
present in the air conditioning system.
Discharge the system. Replace receiver drier. Evacuate and -
check for leaks, and recharge with specified amount of
refrigerant.
2OUO307
- -
HEATERS AND AIR CONDITIONING - Service Adjustment Procedures 24-15
TESTING SYSTEM FOR LEAKS NUFFAD
Liquid
line A leak is likely to occur where two components are connected
\ Liquid line
I together. See the illustration for possible locations.
The Leak Detector Torch is a butane gas-burning torch used to
locate a leak in any part of the refrigeration system. Refrigerant
gas drawn into the sampling or “sniffer” hose will cause the
I
flame to change color in proportion to the size of the leak. A
very small leak will produce a flame varying from yellowish-
green to bright green. A large leak will produce a briliant blue
flame.
Caution
Do not use the lighted detector in any place where
explosive gases, dust or vapors are present. Do not
breathe the fumes that are produced by the burning of
refrigerant gas. Large concentrations of refrigerant in the
presence of a live flame become dangerously toxic.
If the flame remains bright yellow when the tester is removed
from a possible leak point, insufficient air is being drawn in
through the sampling tube, or the copper reaction wire is dirty.
(1) Assemble leak detector as shown in the illustration, and be
Liquid line High pressure sure detector is seated tightly over torch gasket.
hose
2010439 (2) Holding torch upright, screw-in butane charger (clockwise)
until punctured. (Do not use force).
detector torch (3) Screw-out butane charger (anticlockwise) about l/4 turn.
(4) Point torch away from body-then light escaping gas with
match. Always keep torch in upright position.
(5) Adjust flame by turning cartridge in or out as required.
(6) Allow 30 seconds to heat copper reaction wire.
Caution
Never remove butane charger while torch is lighted or
in the presence of any open flame.
Electric leak A (7) Examine all tube connectors and other possible leak points
detector tester by moving the end of the sampling hose from point to
point. Always keep torch in upright position. Since R-12 is
heavier than air, it is good practice to place the open end of
sampling hose directly below point being tested. Be careful
not to pinch sampling tube since this will shut off air supply
to flame and cause a color change.
(8) Watch for a change in the color of the flame.
Small leaks will produce a green color and large leaks a
bright blue color. If leaks are observed at tube fittings,
2OUO338 tighten the connection, using the proper flare wrenches,
and retest.
NOTE
A leakage of refrigerant can be detected by an electric leak
detector that emits a warning sound.
PERFORMANCE TEST N24FWAFa
(1) Park the tested vehicle at the area which is not exposed to
the direct sunlight.
(2) Connect a tachometer and manifold gauge set.
(3) Set the controls of the air conditioner as follows:
Air conditioning switch: A/C-ON position
Mode selection lever: Face position
Temperature control lever: Max. cooling position
Air selection lever: Recirculation position
Blower switch: HI (Fast) position
(4) Start engine and adjust rpm to 1,000 with air conditioner
clutch engaged.
(5) Engine should be warmed up with doors, windows close
and hood open.
(6) Insert a thermometer, to a depth of 20-30 mm (8-I .2 in.),
into the left center air conditioner outlet, and operate the
engine for 20 minutes.
(7) Note the discharge air temperature.
NOTE
If the clutch cycles, take the reading before the clutch
disengages.
PERFORMANCE TEMPERATURE CHART

Garage ambient“C (“F)
temperature 21 (70) 26.7 (80) 32.2 (90) 37.8 (100) 43.3 (110)
Discharge air 2.0-8.0 2.0-8.0 2.0-8.0 4.0-11.0 6.0-14.0

temperature “C (“F) (35.6-46.4) (35.6-46.4) (35.6-46.4) (39.2-51.8) (42.8-57.2)
Compressor
discharge pressure 900-1.300 1.000-1.400 l,lOO-1,500 1,300-1,700 1,500-1,900
(128-186) (142-199) (156-212) (186-242) (212-270)
kPa (psi)
Compressor suction 50-150 80-180 100-200 130-230 ’ 150-250
pressure kPa (psi) (7.1-21.3) (11.4-25.6) (14.2-28.4) (18.5-32.7) (21.3-35.6)
HEATERS AND AIR CONDITIONING - Service Adjustment Procedures 24-Q
REFRIGERANT LEAK REPAIR PROCEDURE N24FtiAO
Lost Charge
If the system has lost all charge due to a leak:
(1) Evacuate the system. (See procedure.)
(2) Charge the system with approximately one pound of
refrigerant.
(3) Check for leaks.
(4) Discharge the system.
(5) Repair leaks.
(6) Replace receiver drier.
Caution
ilectric leak Replacement filter-drier units must be sealed while in
letector tester storage. The drier used in these units will saturate
water quickly upon exposure to the atmosphere. When
installing a drier, have all tools and supplies ready for
quick reassembly to avoid keeping the system open
any longer than necessary.
(7) Evacuate and charge the system.
Low Charge
If the system has not lost all of its refrigerant charge; locate
2OUO333 and repair all leaks. If it is necessary to increase the system
pressure to find the leak (because of an especially low charge)
add of refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the procedure for
correcting low refrigerant level.
CORRECTING LOW REFRIGERANT LEVEL

Since the refrigeration system is completely sealed, refrigerant
level will not be low unless there is a leak in the system. Before
adding refrigerant when the cause of low level is not known,
the system should be tested for leaks. Assuming that leaks
have been corrected without discharging the system, proceed
with partial charge.
Install and connect manifold gauge set.
(1) Close both gauge set manifold valves.
40°C (I 04°F) (2) Connect the suction gauge test hose to the suction port of
20A0463 the compressor. Connect the discharge gauge test hose to
the discharge port.
(3) Connect one end of long test hose to center manifold
outlet, other end to refrigerant dispensing manifold.
(4) Close two dispensing manifold valves and open remaining
dispensing manifold valve. Remove protective cap from
opened valve.
(5) Screw a can of R-12 to the opened manifold valve. Be sure
gasket is in place and in good condition. Tighten refrigerant
can and manifold locking nut to insure a good seal. Do not
overtighten 8 to 11 Nm (6 to 8 ft.lbs.) is sufficient if gasket
is in good condition.
(6) Turn manifold valve (above the refrigerant can) completely
clockwise to puncture the can. This closes the valve and
seals the refrigerant in the can.
Caution
Never heat small cans of refrigerant over 40°C (104°F)
as they may explode.
(7) Place the refrigerant in a large pan of water heated to 52°C
(104°F). Place pan of water containing the refrigerant can
on an accurate scale so the amount of refrigerant added
can be weighed. Open the refrigerant manifold valve.
(8) Purge all air from test hoses. Air in the system will be
trapped in the condenser causing abnormally high dis-
charge pressures and interfering with condensing of the
refrigerant.
(9) Slightly loosen both test hoses at the gauge set manifold.
Tighten the hoses as soon as the air is purged.
(10)Slightly loosen charging hose connection at gauge set
manifold. This will purge air from the charging hose.
Tighten connection as soon as air is purged.
(I l)With vehicle windows open and hood up, operate engine at
1,500 rpm and jump the low pressure switch terminals
located on the receiver drier so the clutch will remain
engaged.
e
(12)Place air conditioner control on air conditioner and place the
. i”
blower switch on high.
(13)lf necessary, block the condenser to maintain a discharge
pressure of 1,422 to 1,520 kPa (206 to 220 psi). System
must be charged through the evaporator suction service
ports as follows:
(a) Slowly open the suction service gauge valve.
Meter flow of refrigerant by adjusting, the suciton
service gauge valve so that pressure registered at the
suction service gauge does not exceed 345 kPa (50 psi).
Keep refrigerant container upright.
(b) Add refrigerant gas until there is no foam visible at the
sight glass.
Add an additional 170 g (6 oz.)
(c) Close the suction gauge valve.
Caution
Too much refrigerant in the system can cause
abnormally high discharge pressures. Care must be
used so that the exact recommended amount or
refrigerant is added after foam clears in the sight
glass.
(d) Close dispensing manifold valve. Remove test hoses
and adapters from the service ports of compressor,
install protective caps at service ports and reconnect
wiring.
(e) Check system performance. (P.24- 16.) A
i-4
HEATERS AND AIR CONDITIONING - Service Adjustment Procedures 241$19
DISCHARGING SYSTEM
-. Since the air conditioning refrigerant system is pressurized, it
will be necessary to completely discharge the system (in a well
ventilated area) before replacing any refrigerant component.
The procedure is as follows:
(1) Install manifold gauge set. Make sure the gauge set valves
are closed before attaching the hoses to the refrigerant
system.
(2) Install a long hose to the manifold gauge set connector.
Run this hose to the oil collector can near a shop exhaust
Oil collector can 2OAO464 system.
A good oil collector can may be made from a large empty
coffee can with a plastic top. Slit the plastic top in the form
of a Y to make an entrance for the refrigerant hose and an
exit for the gas.
(3) Open the compressor discharge and suction line pressure
valves and blow the refrigerant into the oil collector can.
Watch to make sure the hose does not blow out of the
collector can.
(4) When the system has been completely discharged, mea-
sure the amount of oil collected in the can. The amount of
oil measured should be added to the refrigerant system
before it is re-charged. Add new oil-discard the used oil.
Caution
It is important to have the correct amount of oil in the
refrigerant system.
Too little oil will provide inadequate compressor lubrication
and cause a compressor failure. Too much oil will increase
discharge air temperature.
When a IOPAI 7 compressor is installed at the factory, it
contains 80 cc (4.8 cu.in.) of refrigerant oil. While the air
conditioning system is in operation, the oil is carried
through the entire system by the refrigerant.
Some of this oil will be trapped and retained in various parts
of the system.
When the following system components are changed, it is
necessary to add oil to the system to replace the oil being
removed with the component.
Compressor: 30 cc (1.8 cu.in.1
Condenser: 20 cc (1.2 cu.in.1
Evaporator: 30 cc (1.8 cu.in.)
Piping: 10 cc (.6 cu.in.1
Receiver drier: 10 cc (.6 cu.in.1
EVACUATING SYSTEM
Whenever the system has been opened to the atmosphere, it
is absolutely essential that the system be evacuated or
“vacuumed” to remove all the air and moisture. Air in the
refrigerant system causes high compressor discharge pres-
sures, a loss in system performance, and oxidation of the
compressor oil into gum and varnish. Moisture in the re-
frigerant system can cause the expansion valve to malfunction.
Under certain conditions, water can react with the refrigerant
to form destructive acids. It is necessary to adhere to following
procedure to keep air and moisture out of the system.
(1) Check to ensure that there is no internal pressure in the
equipment. If there is an internal pressure, it should be
relieved through the check valve.
(2) Connect the charging hoses of the gauge manifold to the
inlet and outlet check valves of the compressor.
(3) Connect a vacuum pump to the charging hose. Repeat
evacuation in the following sequence.
Repeat
) Start the vacuum pump. three
I- times
20A0465 b
I I
Compound pressure gauge indicates
100 kPa (15 psi.). I
Operate the vacuum pump for mofe
Fourth Stop the vacuum pump.

time I b
Replace the vacuum pump with the
I service can.
stop 1
the Discharge air from inside the charging
vacu- hose.
;Ummp. b
Charge refrigerant from the low pressure
;s”;pf the gauge manifold. [49 kPa (7
Ga;iejmanifold low pressure valve

I
20A0466
Connect the vacuum pump to the charg-

ing hose.
I
NOTE
(1) Do not use the refrigerant pressure to expel air.
(‘2) Do not use the. compressor for evacuation. __ _
(3) Do not operate the compressor In the vacuum condrtlon; shaft seal leaks
could occur.
CHARGING SYSTEM
The refrigerant system must have been evacuated using the
previous procedure before charging.
Charge using only R-l 2 refrigerant. R-12 is available in bulk
tanks or small cans. Follow the safety precautions for handling
R-12 as listed in this group.
Charging with Small Cans
When using disposable cans of this type, follow carefully the
Hot water
40°C (104°F) can manufacturers instructions.
1467 Caution
Never use these cans to charge into the high pressure side
of the system (compressor discharge port) or into a system
that is at high temperature, because the high system
pressures could be transferred into the charging can
causing it to explode.
Keep the refrigerant manifold valves capped when not in use.
Keep a supply of extra refrigerant-can-to-refrigerant-manifold
gaskets on hand so that gaskets can be replaced periodically.
This will insure a good seal without excessive tightening of the
can or the manifold nuts.
(1) Attach center hose from manifold gauge set to refrigerant
dispensing manifold. Turn refrigerant manifold valves com-
pletely anticlockwise so they are fully open.
Remove protective caps from refrigerant manifold.
(2) Screw refrigerant cans into manifold. Be sure manifold-to-
can gasket is in place and in good condition. Tighten can
i and manifold nuts to 8 to 11 Nm (6 to 8 ft.lbs.).
(3) Turn refrigerant manifold valves completely clockwise to
puncture the cans and close the manifold valves.
(4) Purge the air from the charging line by loosening the
charging hose at the gauge set manifold and turning one of
the refrigerant valves anticlockwise to release refrigerant.
When the refrigerant gas starts escaping from the loose
connection, re-tighten the hose.
Caution
Never heat small refrigerant cans over 40°C (104°F) as
they may explode.
(5) Fully open all refrigerant manifold valves being used and
place the cans of refrigerant into a pan containing 40°C
(104°F) water. The water will warm the charging can and
aid in the transfer to the charge into the system. Place the
water pan and refrigerant cans on a scale and note the
weight.
(6) Place air conditioner control on air conditioner and place the
blower switch on high.
(7) Open the discharge and suction gauge valves of the gauge
manifold, and charge gas from the both.
Keep refrigerant container upright.
(8) When suction of refrigerant is saturated, close the dis-
charge and suction gauge valves once, and start the
engine. Fix the engine revolution speed at approx. 1,500
rpm.
(9) Charge through the suction side of the system by slowly
opening the suction manifold valve. Adjust the valve as
necessary so charging pressure does not exceed 345 kPa 6
(50 psi). Maintain the temperature of the water in the pan w’
by adding warm water as necessary.
Note the weight of water added, to ensure accuracy when
determining amount of refrigerant added to system.
(lO)When specified refrigerant charge Max. 925 g (32 oz.) has
entered the system, close the gauge set manifold valves,
refrigerant manifold valves, and reconnnect wiring. Each
can contains 397 g (14 oz.) of R-l 2. Use 2 l/2 cans.
HANDLING TUBING AND FITTINGS
Liquid line
\
I
Dual pressure
switch
Low pressure
Liquid line High pressure hose
20A0440
Kinks in the refrigerant tubing or sharp bends in the Never attempt to rebend formed lines to fit. Use the
refrigerant hose lines will greatly reduce the capac- correct line for the installation you are servicing.
ity of the entire system. High pressures are pro- A good rule for the flexible hose lines is keep the
duced in the system when it is operating. Extreme radius of all bends at least 10 times the diameter of
care must be exercised to make sure that all the hose.
connections are pressure tight. Dirt and moisture Sharper bends will reduce the flow of refrigerant.
can enter the system when it is opened for repair or The flexible hose lines should be routed so that they
replacement of lines or components. The following are at least 80 mm (3 in.) from the exhaust manifold.
precautions must be observed. It is good practice to inspect all flexible hose lines at
The system must be completely discharged before least once a year to make sure they are in good
opening any fitting of connection in the refrigeration condition and properly routed.
system. Open fittings with caution even after the Unified plumbing connections with O-rings. These
system has been discharged. If any pressure is O-rings are not reusable.
noticed as a fitting is loosened, allow trapped
pressure to bleed off very slowly.
HEATERS AND AIR CONDITIONING - Service Adiustment Procedures 24-23
O-RING INSTALLATION
we
(1) Clean sealing surface.
(2) Make sure O-ring does not have any scratches.
(3) Connect fitting, install fastener, and torque to amount
The internal parts of the refrigeration system will remain in
a state of chemical stability as long as pure-moisture-free
R-12 and refrigerant oil is used. Abnormal amounts of dirt,
moisture of air can upset the chemical stability and cause
operational troubles or even serious damage if present in
more than minute quantities.
When it is necessary to open the refrigeration system, have
everything you will need to service the system ready so the
system will not be left open any longer than necessary. Cap
or plug all lines and fittings as soon as they are opened to
prevent the entrance of dirt and moisture. All lines and
components in parts stock should be capped or sealed until
they are ready to be used. All tools, including the refrigerant
dispensing manifold, the gauge set manifold and test hoses
should be kept clean and dry.
2ouo2er
< 1.8L Engine> Tension COMPRESSOR DRIVE BELT ADJUSTMENT N24FJAE

/ wllev
Satisfactory performance of the air conditioning system is
dependent upon drive belt condition and tension. If the proper
tensions are not maintained, belt slippage will greatly reduce air
conditioning performance and drive belt life. To avoid such
adverse effects, the following service procedure should be
followed:
(1) Measure the deflection with a force of IOON (22 Ibs.)
applied to belt mid-point between tension pulley and
compressor pulley.
(2) Any belt that has operated for a minimum of one half-hour
is considered to be a “used” belt. Adjust air conditioning
< drive belt at the time of new-car preparation.
(3) Check drive belt tension at regular service intervals and
adjust as needed.
Standard value:
When a new belt is installed
<1.8L Engine> 4-5 m m (.16-.2 in.)
<2.0L DOHC Engine> 4.5-5 mm (.18-.2 in.)
When the used belt’s tension is adjusted
5 . 5 - 6 m m (.22-.24 in.)
COMPRESSOR NOISE NUFIAB
When investigating an air conditioning related noise, you must

first know the conditions when the noise occurs. These
conditions are: weather, vehicle speed, in gear or neutral,
engine temperature or any other special conditions.
Noises that develop during air conditioning operation can often
be misleading. For example: what sounds like a failed front
bearing or connecting rod, may be caused by loose bolts, nuts,
mounting brackets, or a loose clutch assembly. Verify acces-
sory drive belt tension (power steering, or alternator).
Improper accessory drive belt tension can cause a misleading
noise when the compressor is engaged and little or no noise
when the compressor is disengaged.
Drive belts are speed sensitive. That is, at different engine
speeds, and depending upon belt tension, belts can develop
unusual noises that are often mistaken for mechanical prob-
lems within the compressor.
Adjustment Procedures
(1) Select a quiet area for testing. Duplicate conditions as
much as possible. Switch compressor on and off several
times to clearly identify compressor noise.
To duplicate high ambient conditions (high head pressure),
restrict air flow through condenser. Install manifold gauge
set to make sure discharge pressure doesn’t exceed 2,070
kPa (300 psi).
(2) Tighten all compressor mounting bolts, clutch mounting
bolt, and compressor drive belt. Check to assure clutch coil
is tight (no rotation or wobble).
(3) Check refrigerant hoses for rubbing or interference that can
cause unusual noises.
(4) Check refrigerant charge (See “Charging the System”).
(5) Recheck compressor noise as in Step 1.
(6) If noise still exists, loosen compressor mounting bolts and
retorque. Repeat Step 1.
(7) If noise continues, replace compressor and repeat Step 1.
Condenser fan motor relay,
Magnet clutch
relay, Blower POWER RELAY CHECK NUFNAE
motor High
relay Heater relay NOTE
For information concerning the installation position of each
relay, refer to P.24-8.
CONDENSER FAN MOTOR RELAY, MAGNET CLUTCH
RELAY, BLOWER MOTOR HIGH RELAY, HEATER RELAY
Check for continuity between the terminals when- the battery
power-supply is applied to terminal (2). and terminal (4) is
grounded.
1 When current flows 1 Between terminals l-3 1 Continuity 1
I When no current
flows
Between terminals l-3 No continuity
Between terminals 2-4 Continuity
ML0312 16W908
Kinks in the refrigerant tubing or sharp bends in the Never attempt to rebend formed lines to fit. Use the
refrigerant hose lines will greatly reduce the capac- correct line for the installation you are servicing.
ity of the entire system. High pressures are pro- A good rule for the flexible hose lines is keep the
duced in the system when it is operating. Extreme radius of all bends at least 10 times the diameter of
care must be exercised to make sure that all the hose.
connections are pressure tight. Dirt and moisture Sharper bends will reduce the flow of refrigerant.
can enter the system when it is opened for repair or The flexible hose lines should be routed so that they
replacement of lines or components. The following are at least 80 mm (3 in.) from the exhaust manifold.
precautions must be observed. It is good practice to inspect all flexible hose lines at
The system must be completely discharged before least once a year to make sure they are in good
opening any fitting of connection in the refrigeration condition and properly routed. F
system. Open fittings with caution even after the Unified plumbing connections with O-rings. These 4’
system has been discharged. If any pressure is O-rings are not reusable.
noticed as a fitting is loosened, allow trapped
pressure to bleed off very slowly.
CONDENSER FAN MOTOR HIGH-LOW SELECTING RELAY
Check for continuity between the term,inals when the battery
power-supply is applied to terminal (5), and terminal (3) is
grounded.
I When current flows 1 Between terminals l-2 1 Continuity 1
16A1077
When no current
flows
IDLE-UP OPERATION CHECK N24FoAA
(I) Before inspection and adjustment set vehicle in the

following condition:
l Lights, electric cooling fan and accessories: Set to OFF
l Transaxle: Neutral (N or P for vehicles with A/T)
l Steering wheel: Straightforward
(2) Check whether or not the idling speed is the standard
value.
20AO499 Standard value: 4.8L Engine> 700 rpm
<2.0L DOHC Engine> 750 rpm
NOTE
There is no necessity to make an adjustment, because the
idling speed is automatically adjusted by the ISC” system.
If, however, there occurs a deviation from the standard
value for some reason, check the ISC” system.
(3) Check to be sure that the idlig speed becomes the standard
value when the air conditioner switch is switched ON and
the air conditioner is activated.
Standard value: 850 rpm
NOTE
There is no necessity to make an adjustment, because the
idling speed is automatically adjusted by the ISC” system.
If, however, there occurs a deviation from the standard
value for some reason, check the ISC” system.
ISC: Idle Speed Control
24-26 HEATERS AND AIR CONDITIONING - Heater Control Assembly
HEATER CONTROL ASSEMBLY

2OAO430
Removal steps
1. Stopper Pre-removal Operation
2. Glove box assembly @Removal of Radio and Tape Player
l + 3. Connection for the air-selection control (Refer to GROUP 8-Audio System.)
wire
4. Dial knob
l * ;: CI.Z;Er air outlet assembly
7. Cluster panel assembly (A) (Refer to GROUP 8-Audio System.)
8. Cluster panel assembly(B)
9. Plug
10. Knee protecter
11. Hood lock release handle
12. Shower duct, LH
13. Lap cooler duct
l + 14. Connection for the mode control wire NOTE
l * 15. Connection for the temperature control (1) Reverse the removal procedures to reinstall.
wire (2) 4e : Refer to “Service Points of Removal”.
16. Heater control assembly (3) l 4 : Refer to “Service Points of Installation”.
HEATERS AND AIR CONDITIONING - Heater Control Assembly 24-27
SERVICE POINTS OF REMOVAL N24GBAL
5. REMOVAL OF CENTER AIR OUTLET ASSEMBLY

Disengaging the tabs of the center air outlet assembly with
a flat tip (-1 screwdriver, remove the center air outlet
assembly with a plastic trim tool.
lQA0274
INSPECTION N24GCAG
BLOWER SWITCH
Operate the switch, and check the continuity between the
terminals.
Termina’ 5 3 6 2 7 8 1 4
OFF
l (Low) o - - o o---o
o (Medium first step) 0 f-l e-0

0 (Medium second step) 0-0
0 (High) 0 1 I I lo oln
NOTE
D0 indicates that there is continuity between the terminals.
20A0408
24-28 HEATERS AND AIR CONDITIONING - Heater Control Assembly
SERVICE POINTS OF INSTALLATION N24GOAO
15. INSTALLATION OF TEMPERATURE CONTROL WIRE

Connect the temperature control wire to the blend air
damper lever by following the steps below.
(1) Move the temperature control lever to the rightmost
position. (“HOT” position)
(2) With the blend air damper lever pressed completely
downward in the direction indicated by the arrow,
connect the inner cable of the temperature control wire
to the end of the blend air damper lever, and then
secure the outer cable by using a clip.
14. INSTALLATION OF MODE SELECTION CONTROL WIRE
Connect the mode selection control wire to the mode
selection damper lever by following the steps below.
(1) Move the mode selection lever to the $$ position.
(2) With the mode selection damper lever pressed inward
in the direction indicated by the arrow, connect the
inner cable of the mode selection control wire to the
end of the mode selection lever, and then secure the
outer cable by using a clip.
3. INSTALLATlON OF AIR SELECTION CONTROL WIRE

Connect the air selection control wire to the air selection
damper lever by following the steps below.
(1) Move the air selection control lever to the & posi-
tion.
(2) With the air selection damper lever pressed inward in
the direction indicated by the arrow, connect the inner
cable of the air selection control wire to the end of the
II air selection lever, and then secure the outer cable by
using a clip.
IT 20AO409
HEATERS AND AIR CONDITIONING - Resistor
RESISTOR
r
20A0448
R e m o v a l s t e p s
1. Stopper
2. Connector for the resistor
3. Resistor
NOTE
INSPECTION N2UCAC
RESISTOR CHECK
(1) Remove the stopper and tilt the glove box downward and
forward.
(2) Disconnect the connector for the resistor.
(3) Using a circuit tester, measure the resistance between the
terminals indicated below.
The condition can be considered satisfactory if the value
measured at this time is equivalent to the standard value.
20A0447
Standard value
Terminals measured Standard value P

Between terminals O-0 Approx. 1.7- ‘I .96
Between terminals @-@I Approx. 0.81-0.93
Between terminals 0-0 Approx. 0.29-0.33
24-30 HEATERS AND AIR CONDITIONING - Air Conditioner Switch
AIR CONDITIONER SWITCH

REMOVAL AND INSTALLATION - - N24OA..
- 2OAO419
al Operation
@Removal of
-. R;tdio _.- Tane Plaver
.--._ and .-, -
NOTE Operation /
l Installation of Radio and Tape Player
(Refer to GROUP 8-Audio System.)
I. Air conditioner switch connector
CL
77 -. , .,a -.,a
7 Air ,-,..-,.-. -.....,.
rnnditinner switch , .._._.__
Reverse _..- removal
.-...-.-.orocedures
r----- --to reinstall.
I

-----A
N24QBAF
2. REMOVAL OF AIR CONDITIONER SWITCH

Remove the radio set, and insert hand to the back of the
cluster panel assembly through the produced opening.
Catching the air conditioner switch on the right and left
sides, push it toward you for removal.
INSPECTION N24OCACa
AIR CONDITIONER SWITCH CHECK

(1) Remove the heater control panel.
(2) Remove the connector for the air conditioner switch, and
then check for continuity as described below.
20A0427
NOTE
(1) The 0-0 symbol indicates continuity.
(2) The broken line (-----) indicates the connection
during ECONOMY use.
(3) The chain line (- -----) indicates the connection
during air conditioner use.
20A0199
HEATERS AND AIR CONDITIONING - Heater Unit 24-31
HEATER UNIT
REMOVAL AND INSTALLATION N24m-

eDraining of Engine Coolant *Supplying of Coolant
(Refer to GROUP 7-Service Adjust- (Refer to GROUP 7-Service Adjust-
ment Procedures.) ment Procedures.)
@Removal of Floor Console and In- l installation of Floor Console and
strument Panel Instrument Panel
(Refer to GROUP 23-Floor Console (Refer to GROUP 23-Floor Console
and Instrument Panel.) and Instrument Panel.)
<Vehicles without air conditioner>
shower duct> J
Removal steps
1. Center reinforcement
2. Shower duct (R.H.)
3. Distribution foot duct
;: ;Z;;er duct assembly
6. Evaporator NOTE
:z 7. Heater unit (1) Reverse the removal procedures to reinstall.
8. Lap cooler duct (A) (2) 4* : Refer to “Service Points of Removal”.
24-32 HEATERS AND AIR CONDITIONING - Heater Unit
SERVICE POINTS OF REMOVAL NMISAO
6. REMOVAL OF EVAPORATER
Refer to GROUP 24-34.
7. REMOVAL OF HEATER UNIT

NOTE
In order to prevent bolts from falling into the blower
assembly, set the inside/outside air-selection damper to
the position that permits outside air introduction.
INSPECTION N24lcAa
l Check the operation of dampers and link mechanism.
l Check the heater core for clogging and water leakage.
HEATER CORE REPLACEMENT N24lDAH
(1) Remove the heater unit.

(2) Remove the plate.
20A0417
(3) Pull out the heater core from the heater unit.
(4) Insert the heater core into the heater unit.
NOTE
This work must be done carefully so as not to damage the
fin part or the pad part.
(5) Install the plate.
(6) Install the heater unit.
HEATERS AND AIR CONDITIONING - Blower Assemblv 24-33
BLOWER ASSEMBLY
-- REMOVAL AND INSTALLATION NUKA-
1. Shower duct R.H. <if so equipped>

2. Hose 20A0428
+4 3. Blower motor assembly
l 4.- Packing
- .... NOTE
5. t-an lnstallatlon nut (1)Reverse the removal procedures to reinstall.
6. Fan (2) l 4 : Refer to “Service Points of installation”.
INSPECTION N24KCAL
l Check for bending or abnormal deflection of the rotating

shaft of the blower motor assembly.
l Check for cracking or deterioration of the packing.
l Check for damage to the fan.
l Check for damage to the blower case.
l Check the operation of the inside/outside air-selection
damper, and for damage.
BLOWER MOTOR ASSEMBLY CHECK

(1) Disconnect the blower motor terminals.
(2) Connect the blower motor terminals directly to the battery
and check that the blower motor operates smoothly.
(3) Next, reverse the polarity and check that the blower motor
operates smoothly in the reverse direction.
SERVICE POINTS OF INSTALLATION NUKDAF
4. INSTALLATION OF PACKING
If the packing is cracked, replace with a new one.
3. INSTALLATION OF BLOWER MOTOR ASSEMBLY
Before installing the blower motor assembly, carefully
clean away any dust, dirt, etc. adhering to the inner surface
of the blower case.
ZOAO50
24-34 HEATERS AND AIR CONDITIONING - Evaporator
EVAPORATOR
1 Pre-removal Operation 1 Post-installation Operation
aDischarge of Refrigerant l charging of Refrigerant
(Refer to P.24.19.) (Refer to P.24-21.)
l Checking for Refrigerant Ga:
(Refer to P.24-16.)
Removal steps
N l + 1. Liquid pipe and suction hose connection
2. O-ring
3. Stopper
4. Glove box 2OAO424
5. Lower frame
6. Shower duct R.H. <if so equipped>
7. Body wiring harness and air conditioner
wiring harness connection NOTE
8. Air conditioner control unit (1) Reverse the removal procedures to reinstall.
9. Drain hose (2) ++ : Refer to “Service Points of Removal”.
10. Evaporater (3) l : Refer to “Service Points of Installation”.
SERVICE POINTS OF REMOVAL N24RBAHa
1. DISCONNECTION OF LIQUID PIPE AND SUCTION

HOSE
If the hoses or pipes are disconnected, cap the hoses or
pipes with a blank plug to prevent entry of dust, dirt, and
water.
INSPECTION N24RCAA
l Check for damage of the evaporator fin part.

l Check for damage or collapse of the drain hose.
l Check for peeling or cracking of the insulator.
AIR-OUTLET SENSOR AND AIR-INLET SENSOR CHECK
For information concerning the checking procedures, refer to
P.24-13.
SERVICE POINTS OF INSTALLATION N24RDAK
1. CONNECTION OF LIQUID PIPE AND SUCTION HOSE

For information concerning the installation procedures,
refer to P.24-23.
HEATERS AND AIR CONDITIONING - Evaporator 24-35
DISASSEMBLY AND REASSEMBLY NURE--
3 ZOAO457
Disassembly steps
1. Wiring harness
2. Air conditioner control unit
4* 3. Clips
4. Evaporater case (upper)
5. Air inlet sensor
6. Air therm0 sensor
7. Evaporater case (lower)
8. Evaporater assembly
9. Grommet
IO. Insulator NOTE
11. Rubber insulator (1) Reverse the disassembly procedures to reassyyble
12. Clip (2) ~~ : Refer to “Service Points of Disassembly,
+) ++ 13. Expansion valve (3) +4 : Refer to “Service Points of Reassembly
14. O-ring (4) m : Non-reusable parts.
.
24-36 HEATERS AND AIR CONDITIONING - Evaporator
SERVICE POINTS OF DISASSEMBLY N24nFAE
3. REMOVAL OF CLIPS
Remove the clips with a flat-blade. screwdriver covered
with a shop towel to prevent damage to case surfaces.
2OAO323
13. REMOVAL OF EXPANSION VALVE

Loosen the flare nut by using two wrenches. (for both the
inlet and outlet.)
Expansi
valve Rubber insulator
Clip 2OAO324
O-ring SERVICE POINTS OF REASSEMBLY N24nNAJ

13. APPLICATION OF COMPRESSOR OIL TO EXPANSION
VALVE AND O-RINGS
Apply compressor oil to the O-rings and expansion valve of
the evaporator assembly.
HEATERS AND AIR CONDITIONING - ComDressor 24-37
COMPRESSOR <7.8L Engine>
em REMOVAL AND INSTALLATION
F) Post-installation Operation
@Charging of Refrigerant
(Refer to P.24-21.)
*Removal of the distributor Cap @Adjustment of Compressor Drive
Belt (Refer to P.24-23.)
*Checking for Gas Leakage
(Refer to P.24-15.)
*Performance Test
(Refer to P.24-16.)
2 13-15 ft.lbs.
4 5 - 5 5 Nm H 1 2 1 1
- 1 0
2OAO456
Removal steps of compressor drive belt and Removal steps of compressor

tension pulley 4* 1. Compressor drive belt
l * 1, Compressor drive belt 9. Magnetic clutch harness connector
2. Tension pulley assembly installation bolt +e l * 10. Suction hose connection
3. Tension pulley assembly +e I)+ 11. Discharge hose connection
4. Bolt l a 12. O-rings
5. Tension pulley +* l + 13. Compressor
6. Bolt 14. Compressor bracket
7. Adjustment plate
8. Tension pulley bracket
NOTE
(2) l * : Refer to “Service Points of Removal”.
(3) W : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts.
24-38 HEATERS AND AIR CONDITIONING - Compressor
SERVICE POINTS OF REMOVAL N248BACa
1. REMOVAL OF COMPRESSOR DRIVE BELT A;i

(1) Loosen “A” for holding the tension pulley.
(2) Loosen bolt “B” for adjustment, and remove the 4
compressor drive belt.
10. DISCONNECTION OF SUCTION HOSE/ 11. DIS-
CHARGE HOSE
If the hoses are disconnected, cap the hoses with a blank
plug to prevent entry of dust, dirt, and water.
2OAOO87
13. REMOVAL OF COMPRESSOR

Caution
Lay the towel on the brake tube to protect them. When
install the compressor, do not damage the brake tubes.
This work must be done carefully so as not to spill the
compressor oil.
INSPECTION N248CAC
l Checking for heat damage of the tension pulley.

l Check for excessive play or deflection of the tension pulley.
l Check for unusual wear of the tension pulley. /J+-
l Check for hardening of the compressor drive belt.
l Check for unusual wear or abrasion of the compressor drive &’
belt.
CONTINUITY CHECK OF THE COMPRESSOR’S MAGNETIC

CLUTCH
(1) Disconnect the compressor’s connector.
(2) Check to be sure that there is continuity between body

ground and terminal @ at the compressor side.
HEATERS AND AIR CONDITIONING - Compressor 24-39
OPERATION CHECK OF THE COMPRESSOR’S MAGNETIC
CLUTCH
(1) Disconnect the compressor’s connector.
\ / 20A0400
(2) Connect terminal @ at the compressor side to the positive

(+) terminal of the battery, and ground the negative (-)
terminal of the battery to the compressor.
(3) The condition of the compressor’s magnetic clutch can be
considered satisfactory if the operation sound (a “click”
sound) of the magnetic clutch can be heard when this
check is made.
20R0507
SERVICE POINTS OF INSTALLATION N248DADa
13. INSTALLATION OF COMPRESSOR

If a new compressor is installed, first adjust the amount of
oil according to the procedures described below, and then
install the compressor.
(1) Measure the amount (X cc) of oil within the removed
compressor.
(2) Wipe away (from the new compressor) the amount of
oil calculated according to the following formula, and
then install the new compressor.
New compressor oil amount 80 cc (4.9 cu.in.) - X cc =
Y cc
NOTE
Y cc indicates the amount of oil in the refrigerant line,
the condenser, the cooling unit, etc.
12. CONNECTION OF O-RING/ 11. DISCHARGE HOSE/

10. SUCTION HOSE
(1) Take care that the O-rings are not caught, crushed or
cracked.
t1
(2) Since the O-ring size of suction hose is different from
that of discharge hose, be sure to connection correctly.
/
24-40 HEATERS AND AIR CONDITIONING - Compressor
COMPRESSOR <2.0L DOHC Engine>
REMOVAL AND INSTALLATION N24SA.-

aDischarge of Refrigerant *Installation of VSV Bracket
(Refer to P.24-19.) <2.0L Turbo>
l Removal of VSV Bracket on the *Installation of Center Bearin!
Cowl Top <2.0L Turbo> Bracket Mounting Bolt <AWD;
*Disconnection of High-tension (Refer to GROUP 2-Drive Shaft.
Cables and Connections for Igni- *Connection of High-tensior
tion Coil etc. Cables and Connections for lgni
*Removal of Center Bearing tion Coil etc.
Bracket Mounting Bolt <AWD> *Adjustment of Compressor Drivt
(Referto GROUP 2-Drive Shaft.) Belt (Refer to P.24-23.)
Kharging of Refrigerant
(Refer to P.24-21.)
l ehecking for Gas ‘Leakage
(Refer to P.24-15.)
l Performance Test
(Refer to P.24-16.)
23-34 ft.lbs.
45-55 Nm
33-39 ft.lbs.
2OAO4.58
Removal steps of compressor drive belt and Removal steps of compressor

tension pulley 1. Alternator drive belt
1. Alternator drive belt l * 2. Tension pulley assembly installation bolt
4* 2. Tension pulley assembly installation bolt l + 3. Tension pulley assembly
I)+ 3. Tension pulley assembly l + 4. Compressor drive belt
~~ 2: Grpressor dnve b e l t 10. Magnetic clutch harness connector
+* l * 11. Suction hose connection
6. Tension pulley l + 12. Discharge hose connection
7. Bolt l + 13. O-rings
8. Adjustment plate ** l * 14. Compressor
9. Tension pulley bracket 15. Compressor bracket
NOTE
HEATERS AND AIR CONDITIONING - Compressor 24-41
SERVICE POINTS OF REMOVAL NusenD
2. REMOVAL OF TENSION PULLEY ASSEMBLY., lN-
STALLATION BOLTS
(1) After loosening nut A (for holding the tension pulley),
loosen bolt B (for adjustment) and reduce the tension of
the compressor drive belt to zero.
(2) Remove the tension pulley assembly installation bolts:
and then remove the tension pulley assembly together
with the compressor drive belt.
2OPOO12 11. DISCONNECTION OF SUCTION HOSE / 12. DIS-
CHARGE HOSE
Refer to P.24-38.
14. REMOVAL OF COMPRESSOR
Refer to P.24-38.
INSPECTION N24SCAD
Refer to P.24-38.
CONTINUITY AND OPERATION CHECK OF THE COM-
PRESSOR’S MAGNETIC CLUTCH
Refer to P.24-38.
SERVICE POINTS 03: INSTALLATION N24SDAEa
14. INSTALLATION OF COMPRESSOR

Refer to P.24-39.
13. CONNECTION OF 0-RING/lS. DISCHARGE HOSE/
11. SUCTION HOSE
Refer to P.24-39.
4. INSTALLATION OF COMPRESSOR DRIVE BELT/3.

TENSION PULLEY ASSEMBLY
Attach the compressor drive belt to the crankshaft pulley
and the compressor’s pulley, and then install the tension
pulley assembly.
NOTE
(1) Hold the tension pulley assembly so that the compres-
sor drive belt does not slip out of place; and while doing
so install the tension pulley assembly.
Air condltloner compressor
(2) Install the tension pulley assembly installation bolts in
the @ + @ sequence.
COMPRESSOR
24-28 N m
1 8 - 2 1 ft.lbs.
Magnetic clutch disassembly steps Shaft seal disassembly steps

4eW ;. tIu;h hub l + ;. F;;t housing
4*
3: Snap ring 9: Felt holder
4* 4.Rotor 10. Snap ring
5. Snap ring 4e l + 11. Shaft seal
l 4 6. Clutch coil 12. O-ring
NOTE
(2) ~~ : Refer to “Service Points of Disassembly”.
\\ I SERVICE POINTS OF DISASSEMBLY N24SFAC
1. REMOVAL OF CLUTCH HUB

(1) Fix the compressor with a vise. At this time, the rear
housing of the compressor must be in contact with the
vise.
(2) If the clutch hub cannot be pulled off by hand, screw in
an 8 mm (.315 in.) completely threaded bolt so as to
raise the clutch hub so it can be removed.
2OW857
4. REMOVAL OF ROTOR
Using a plastic hammer, lightly tap the rotor off the shaft.
HEATERS AND AIR CONDITIONING - Compiessor 24-43
8. REMOVAL OF FELT
Using a flat-tip 0 screwdriver, remove the felt from the
front housing.
11. REMOVAL OF SHAFT SEAL

Using a flat-tip 0 screwdriver, remove the shaft seal from
the front housing.
INSPECTION N24TGAH
l Check the surface of the clutch hub for scoring or bluing.

l Check the surface of the rotor for scoring or bluing.
l Check the sealing surfaces for cracks, scratches and
deformation.
l Check the front housing for cracks or scoring on the sealing
surfaces.
l Check the compressor shaft for scoring.
SERVICE POINTS OF REASSEMBLY N24StiAC
11. INSTALLATION OF SHAFT SEAL

(1) Lubricate the shaft seal with specified compressor oil.
Specified compressor oil:
DENS0 OIL 6 or SUNISO 5GS
(2) Set the shaft seal to the front housing so that the
projection side of the center ring is at the shaft seal
2OW660 side.
(3) Using a 21 mm (.83 in,) socket, install the shaft seal.
7. INSTALLATION OF FRONT HOUSING
(1) Apply the specified compressor oil on the shaft.
Specified compressor oil:
DENS0 OIL 6 or SUNISO 5GS
(2) Taking care to prevent injuring the lip area of the shaft
tool, mount the front housing.
2OW862
(3) Mount the bolt on the shaft, and then measure the
shaft starting torque.
Standard value: 5.0 Nm (43 in.lbs.) or less
(4) Remove the bolt from the shaft.
24-44 HEATERS AND AIR CONDITIONING - Coinpressiir
6. INSTALLATION OF CLUTCH CO&
The clutch coil must be aligned with the pin in, the
compression housing.
1. INSTALLATION OF CLUTCH HUB

(1) Connect the magnetic clutch to the battery.
(2) The clutch hub will be attracted to and fit closely to the
rotor.
(3) Use ‘a shim(s) to adjust so that the -amount of
movement of the clutch hub is as described below.
12” NOTE
l-l Remove clearance adjusting shims to decrease clutch
2OW863
clearance. Add shims selected from the following table
to increase clutch celarance.
Clearance Adjustment Shims
Part No. Thickness

I 949013-7480 1 0.1 mm (.004 in.) 1
I 949013-7680 1 0.2 mm LOO8 in.) 1
949013-7510 0.5 mm LO20 in.)
I
3 , z,
0’
i,
,,
HEATERS AND AIR CONDITIONING - c ondenser and Condenser Fan Motor 24i45
CONDENSER AND CONDENSER FAN MOTOR
_-- REMOVAL AND INSTALLATION NZITA-
Pre-removal Operation of Post-installation Operatior

Condenser of Condenser
l Discharge of Refrigerant l charging of Refrigerant
*Checking for Gas Leakage
(Refer to P.24-15.)
@Performance Test
(Refer to P.24-16.)
Removal of condenser
1. Condenser fan motor connecter
<Except 1.8L>
<Except 1.8L>
3. Radiator fan motor connecter
<2.0L.Turbo>
4. Therm0 sensor connecter <2.0L.Turbo>
4* 5. Radiator fan motor assembly
<2.0L.Turbo>
6. Upper insulator
+e ~~ 7. Discharge pipe connection
l * l + 8. Liquid pipe connection
4* 9. Condenser
Removal of condenser fan motor

1, Condenser fan motor connecter
NOTE
(3) l 4 : Refer to “Service Points of Installation”
SERVICE POINTS OF REMOVAL N24TBAF
5. REMOVAL OF RADIATOR FAN MOTOR ASSEMBLY

To remove the radiator fan motor assembly, )~ll it out,
keeping the radiator lifted.
7. DISCONNECTION OF DISCHARGE PIPE/8. LIQUID
PIPE
If the hoses are disconnected, cap the hoses with a blank
plug to prevent entry of dust, dirt, and water.
9. REMOVAL OF CONDENSER
Move the radiator toward the engine, and then remove the
condenser upward.
24-46 HEATERS AND AIR CONDITIONING - on
c denser and Condenser Fan Motor
INSPECTION ntarTua
l Check the condenser fin for crushing or other damage.,
l Check the condenser’s high-pressure hose and pipe in-
stallation parts for damage or deformation.
l Check the condenser fan shroud for damage.
CONDENSER FAN MOTOR CHECK

(1) Disconnect the connection of the connector for the
condenser fan motor.
(2) Check to be sure that the condenser fan motor operates

when battery voltage is applied to terminal @I and terminal
@ is grounded.
RESISTOR CHECK
(1) Disconnect the connection of the connector for the
resistor, and then measure the resistance between termi-
nals.
(2) The condition can be considered satisfactory if the mea-

sured resistance is within the range noted below.
Standard value: 0.26-0.32 52
SERVICE POINTS OF INSTALLATtON N24lVAE
8. CONNECTION OF LIQUID PIPE/7. DISCHARGE PIPE

Refer to P.24-23.
20A0407
-
HEATERS AND AIR CONDITIONING - Refrigerant Line 24-47
REFRIGERANT LINE
-- REMOVAL AND INSTALLATION N24UA-

*Discharge of the Refrigerant @Installation of Air-cleaner Bracket
(Refer to P.24-19.) and Air-cleaner (Refer to GROUP
@Removal of Battery and Reserve 11 -Air-cleaner.)
Tank l installation of Battery and Re-
@Removal of Air-cleaner and Air serve tank
cleaner Bracket (Refer to GROUF Kharging of Refrigerant
1 1 -Air-cleaner.) (Refer to P.24-21.)
@Checking for Gas Leakage
(Refer to P.24-15.)
@Performance Test
(Refer to P.24-16.)
9-11 Nm ,
7-8 ft.lbs.
20AO502
Removal steps
I. Flange cover
I)+ 2. Suction hose
3. O-ring
4. Clamp
I)* 5. Discharge hose
6. O-ring NOTE
7. Dual pressure switch connector (1) Reverse the removal procedures to reinstall.
(2) I)4 : Refer to “Service Points of Installation”.
8. Clamp (3) N : Non-reusable parts.
e+ 9. Liquid pipe (4) For information concerning the O-ring indicated by the *
10. O-ring symbo\. refer to P.24.23.
11, Dual pressure switch (5) plug the disconnected hose, pipe, etc, to Prevent dust.
12. Discharge pipe dirt, foreign material, etc. from entering the Openings.
24-48 HEATERS AND AIR CONDITIONING - Refrigerant Line
9. INSTALLATION OF LIQUID PIPE
Caution
1. Keep the gap more than 5 mm (.2 in.) between
liquid pipe and clutch tube.
2. Keep the gap more than 15 mm (.6 in.) betWeen
liquid pipe connected condenser and body.
5. INSTALLATION OF DISCHARGE HOSE
Caution
Keep the gap more than 25 mm (1 in.1 between
accelerator cable and discharge hose.
2. INSTALLATION OF SUCTION HOSE

Caution
Make sure that suction hose does not interfere with
heater hose and mission cable.
HEATERS AND AIR CONDITIONING - Ventilators (Instrument Panel) 24-49
VENTILATORS (INSTRUMENT PANEL)
I- - REMOVAL AND INSTALLATION
16
,’ ! ‘\
19 < !.a n
2OAO420
6. Lap cooler duct (B)

a* 7. Center air outlet assembly
8. Shower duct R’H.
+* l a 9. Instrument panel
10. Distribution foot duct
11. Center duct assembly
12. Lao cooler duct IA)
13. AiFduct (A)
14. Air duct (B)
15. Distribution duct
16. Side defroster hoses
17. Defroster nozzle assembly
18. Side defroster grilles
Removal steps 19. Side air outlet assembly
1. Plug
2. Knee protecter NOTE
3. Hood lock release handle (1) Reverse the removal procedures to reinstall.
4. Lap cooler grille (2) l * : Refer to “Service Points of Removal”.
5. Shower duct L.H. (3) l a : Refer to “Service Points of Installation”.
SERVICE POINTS OF REMOVAL NZNBAG
7. REMOVAL OF CENTER AIR OUTLET ASSEMBLY/

9. INSTRUMENT PANEL
SERVICE POINTS OF INSTAUAT-ION

9. INSTALLATION OF INSTRUMENT PANEL
24-50 HEATERS AND AIR CONDITIONING - Ventilators (Air Inlet and Air Outlet)
VENTILATORS (AIR INLET AND AIR OUTLET) ‘- ’

Inlet garnish removal steps 6. Automatic seat belt motor fastening bolts
l + 1. Windshield wiper arms and screws
2. Front deck garnish 7. Side protect moulding quarter
3. Inlet garnish (right) l * 8. Rear ventilation duct
4. Inlet garnish (left)
!PTkeverse the removal procedures to reinstall.
Rear ventilation removal steps (2) +* : Refer to “Service Point of Removal:.
l * 5. Quarter trim (3) l * : Refer to “Service Points of Installation”
SERVICE POINTS OF REMOVAL N24YEAC
5. REMOVAL OF QUARTER TRIM ’

Refer to GROUP 23-Trims.
6. REMOVAL OF AUTOMATIC SEAT BELT MOTOR
FASTENING BOLTS AND SCREWS
Remove the bolts and screws which fasten the automatic
seat belt motor, and slide the motor for working.
8. REMOVAL OF REAR VENTllATlON DUCT

For removal and installation, pass the rear ventilator duct
through the opening of the automatic seat belt motor as
illustrated.
1. INSTALLATION OF WINDSHIELD WIPER ARMS
Refer to GROUP 8-Windshield wipers.
HEATERS AND AIR CONDITIONING - Engine Coolant Temperature Switch 24-51
ENGINE COOLANT TEMPERATURE SWITCH <2.0L DOHC Engine>
-. REMOVAL AND INSTALLATION N24xA-
1 t o GROUP f-service Adjust-1

ment Procedures.)
22-28 ft.lbs.
Removal steps
1. Engine coolant temperature switch
connector (2-pin) NOTE
.4 2. Engine coolant temperature switch (1) Reverse the removal procedures to reinstall.
(always-closed type) (2) l 4 : Refer to “Service Points of Installation”.
INSPECTION N24XcAA
ENGINE COOLANT TEMPERATURE SWITCH (ALWAYS-

CLOSED TYPE CHECK)
(1) Remove the engine coolant temperature switch from the
water outlet fitting.
(2) Immerse the engine coolant temperature switch in oil and
heat by a gas stove or similar method so as to increase the
oil temperature.
(3) Check to be sure that the engine coolant temperature
switch is switched OFF when the oil temperature reaches
the standard value.
Standard value: 112- 118°C (233-244°F)
Caution
Use engine oil for this test; stir it well while heating,
and do not heat more than necessary.
SERVICE POINTS OF INSTALLATION N24XDM
2. INSTALLATION OF ENGINE COOLANT TEMPERATURE

SWITCH (ALWAYS-CLOSED TYPE)
Apply a coating of the specified sealant to the threaded
parts and then install the engine coolant temperature
switches.
Specified sealant: MOPAR Part No.4318034 or ewiva-
lent
20A0190 I
NPTES > :,’
.^
EMISSION CONTROL
SYSTEMS
CONTENTS N25AA-
CATALYTIC CONVERTER ............................... 20 EXHAUST GAS RECIRCULATION (EGR)

SYSTEM ........................................................... 15
CRANKCASE EMISSION CONTROL Air-fuel Ratio Control (MPI) System ............ 20
SYSTEM ........................................................... 7
Components Location ................................... 15
Components Location ................................... 7
EGR Control Solenoid Valve
Crankcase Ventilation System <California> ................................................. 19
Inspection ...................................................... 8
EGR System Inspection ............................... 17
Positive Crankcase Ventilation Valve ........... 8
EGR Temperature Sensor <California> ...... 19
EVAPORATIVE EMISSION CONTROL EGR Valve ..................................................... 18
SYSTEM ........................................................... 9 Therm0 Valve <Federal and Canada-
Air Conditioner Switch ................................. 14 2.0L DOHC Engine> ................................... 18
Air Flow Sensor, Engine Coolant 2
Temperature Sensor and Intake Air SPECIFICATIONS .............................................
Temperature Sensor ..................................... 14 General Specifications .................................. 2
Canister ......................................................... 14 Sealant .......................................................... 2
Components Location ................................... 9 Service Specifications ................................... 2
Fuel Filler Cap Inspection ............................ 14 Torque Specifications ................................... 2
Overfill Limiter (Two-way Valve) .................. 14 3
TROUBLESHOOTING ......................................
Purge Control Solenoid Valve ...................... 13
Purge Control System Inspection ................ 11 VACUUM HOSES ........................................... 4
Purge Control Valve <Turbo> ..................... 13 Vacuum Hoses Routing ............................... 4
EMISSION CONTROL SYSTEMS - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS N25CA-
Items Specifications .,:. .r
Crankcase emission control system Closed type with positive crankcase ventilation valve” ‘:
I
Evaporative emission control system Canister storage type
Canister Charcoal type
Exhaust emission control system

Exhaust gas recirculation system
EGR valve Vacuum-activated diaphragm type
<Except Federal and Canada-l .8L Engine>
Therm0 valve Bimetal type
<Federal and Canada-2.0L DOHC Engine>
EGR control solenoid valve <California> Duty cycle solenoid valve
Catalytic converter Monolith type
Location Under floor
SERVICE SPECIFICATIONS N25CB-
Purge-control solenoid valve coil resistance &2 36-44 [at 20°C (68”F)I
Therm0 valve closing temperature “C (“F) 65 (149)
EGR temperature sensor resistance kQ 60-83 [at 50°C (122”F)]
11-14 [at 100°C (212”F)]
EGR control solenoid valve coil resistance S2 36-44 [at 20°C (68”F)]
TORQUE SPECIFICATIONS N25CC-
Items Nm ftlbs.
Positive crankcase ventilation valve 8-12 6-8.5
EGR valve installation bolt
<Federal and Canada-l .8L Engine> IO-15 7.2-10
<2.0L DOHC Engine> 15-22 10-15.5
Therm0 valve <Federal and Canada-2.0L DOHC Engine> 20-40 15-30
EGR temperature sensor 10-12 7.3-8.6
SEALANT
Therm0 valve thread portion MOPAR Part No.4318034 or equivalent
EMISSION CONTROL SYSTEMS - Troubleshooting
TROUBLESHOOTING
-. ., ,_
Engine will not start or hard to Vacuum hose disconnected or damaged Repair or replace
start The EGR valve is not closed
Malfunction of the purge control solenoid
valve
Rough idle or engine stalls The EGR valve is not closed. Repair or replace
Vacuum hose disconnected or damaged
Malfunction of the positive crankcase Replace

ventilation valve
Malfunction of the purge control system Check the system; if there is a problem,
check its component parts
Engine hesitates or poor accel- Malfunction of the exhaust gas recircula- Check the system; if there is a problem,
eration tion system check its component parts
Excessive oil consumption Positive crankcase ventilation line clogged Check positive crankcase ventilation sys-
tem
Poor fuel mileage Malfunction of the exhaust gas recircula- Check the system; if there is a problem,
tion system check its component parts
25-4 EMISSION CONTROL SYSTEMS - Vacuum Hoses
VACUUM HOSES hW7JA-
r”
VACUUM HOSES ROUTING
w..’
<Federal and Canada- 1.8L Engine>
Purge control
/solenoid valve
Canister,
Fuel pressure
regulator
L : Light blue
R: Red 3EM0123
B: Black Vehicle front
<-LCalifornia- 1.8L Engine>
Canister
Throttle body
-Fuel pressure
a
G: Green regulator
Y : Yellow
L : Light blue
R: R e d /
B : Black EGR valve
Vehicle front 3EM0124
EMISSION CONTROL SYSTEMS - Vacuum Hoses 2515
<Federal and Canada-2.0L DOHC Engine Non-Turbo>
Purge control
solenoid valve
Canister
Fuel pressure
regulator
n
Therm0
valve
G: Green
Y: Yellow
L: Light blue
Vehicle front 6EM0191
R: Red
B: Black
<California-2.0L DOHC Engine Non-Turbo>
Purge control
solenoid valve
Cani
Fuel pressure
regulator
EGR control
solenoid valve
EGR valve
G: Green
Y : Yellow 6EM0192
L : Light b l u e Vehicle front
R: Red
B : Black
25-6 EMISSION CONTROL SYSTEMS - Vacuum Hoses
<Federal and Canada-2.0L DOHC Engine Turbo>
Purge control
solenoid valve
Fuel pressure control, /
solenoid valve
Purge control valvg
el pressure regulator
Therm0 valve ’
Turbocharger
Waste gate control

G: Green solenoid valve
Y : Yellow vvasre gate actuator
L : Light blue
R: Red Vehicle front
B : Black
W: White
6EM0222
<California-2.0L DOHC Engine Turbo>

Fuel pressure control
solenoid valve.
1s
Purge control valve Purge control
&+ solenoid valve
Air cleaner \
G: Green
Y : Yellow Waste gate control
L : Lrght b l u e solenord valve
R: Red Waste gate actuator .,~~‘~y:‘;7
B : Black v
W: White Vehicle front
6EM0223
EMISSION CONTROL SYSTEMS - v acuum Hoses/Crankcase Emission Control System 25-7
INSPECTION
(1) Referring to the VACUUM HOSES ROUTING, confirm2
the vacuum hoses are properly connected.
(2) Check the hoses for irregularities (disconnection, loose-
ness, etc.) and confirm that there is no breakage or
damage.
INSTALLATION ’ N2SJDAD
(1) When connecting a hose, firmly press it onto the nipple.

(2) Referring to the VACUUM HOSES ROUTING, connect the
hoses correctly.
CRANKCASE EMISSION CONTROL SYSTEM
COMPONENTS LOCATION
<1.8L Engine>
ventilation valve
Name Symbol
Positive crankcase ventilation valve A
<2.0L DOHC Engine> A

\ T /
Name Symbol
Posltive crankcase ventilation valve A

25-8 EMISSION CONTROL SYSTEMS - Crankcase Emission Control System
CRANKCASE VENTILATION SYSTEM INSPEC-

TION NZSIAAH
After disconnecting the ventilation hose from the positive

crankcase ventilation valve, disconnect the positive crank-
case ventilation valve from the rocker cover, and reconnect
the positive crankcase ventilation valve to the ventilation
hose.
Idle engine, put finger on the opening end of the positive
crankcase ventilation valve, and check that the negative
pressure of the intake manifold is felt with finger.
NOTE
At this time, the plunger Ian the positive crankcase ventila-
tion valve moves back and forth.
(3) If negative pressure is not felt, clean or replace the positive
crankcase ventilation valve.
- POSITIVE CRANKCASE VENTILATION VALVE

Positive crankcase INSPECTION
ventilation valve (1) Remove the positive crankcase ventilation valve.
(2) Insert a thin stick into the positive crankcase ventilation
valve from the threaded side to check that the plunger
moves.
(3) If the plunger does not move, the positive crankcase
ventilation valve is clogged. Clean it or replace.
INSTALLATION
3EM0051
Install the positive crankcase ventilation valve and tighten to
specified torque. i
Specified tightening torque: 8-12 Nm (8-8.5 ft.lbs.)
EMISSION CONTROL SYSTEMS - Evaporative Emission Control System
EVAPORATIVE EMISSION CONTROL SYSTEM

‘2,
COMPONENTS LOCATION
4.81, Engine>
P 4
xl-# i
r
I Symbol 1
I Canister
Purge control solenoid valve A
Purge control
solenoid valve
25-10 EMISSION CONTROL SYSTEMS - Evaporative Emission Control System
<2.0L DOHC Engine>
I
1
Symbol 1
Canister B
I Purge control solenoid valve I A I

Purge control valve <Turbo> C
I
EMISSION CONTROL SYSTEMS - Evaporative Emission Control SYStem 25-m
PURGE CONTROL SYSTEM INSPECTION <Non-Turbo> NZ5lBEK
sensor
I
P+ Engine control unit
lEM0086
(1) Disconnect the vacuum hose (red stripes) from the throttle
body and connect it to a hand vacuum pump.
(2) Plug the nipple from which the vacuum hose is discon-
nected.
(3) Under the engine conditions shown below, check by
applying vacuum from a hand vacuum pump.
When engine is cold-engine coolant temperature:
60% (140°F) or less
Engine operating Applying vacuum
>
When engine is hot-engine coolant temperature:

70°C (158°F) or higher
Engine operating Applying vacuum Result

condition
Idling 375 mmHg Vacuum is maintained

(14.8 in.Hg.1
3,000 rpm within Try wpMw Vacuum leaks
three minutes after vacuum
starting engine
3,000 rpm after 375 mmHg Vacuum will be main-
three minutes (14.8 in.Hg.1 tained momentarily,
have elapsed after which it will
after starting leaks.
engine NOTE
The vacuum will leak
continuously if the
altitude is 2,200 m
(7,200 ft.) or higher,
or the intake air
temperature is 50°C
(122°F) or higher.
PURGE CONTROL SYSTEM INSPECTION <Turbo>

Canister
6EM0215
(1) Disconnect the purge air hose from the air intake hose, and
plug the air intake hose. Then, connect the hand vacuum
pump to the purge air hose.
When engine is cold-engine coolant temperature:
60°C (140°F) or less
11
Engine operating Applying vacuum
When engine is hot-engine coolant temperature:

70°C (158°F) or higher

condition
(14.8 in.Hg.)
3,000 rpm within Try applying Vacuum leaks
three minutes after vacuum
starting engine
3,000 rpm after 375 mmHg Vacuum will be main-
three minutes (14.8 in.Hg.1 tained momentarily,
have elapsed after which it will
after starting leaks.
engine NOTE
The vacuum will leak
continuously if the
altitude is 2,200 m
(7,200 ft.) or higher,
or the intake air
temperature is 50°C
(122°F) or higher.
EMISSION CONTROL SYSTEMS - Evaporative Emission Control System 25-W
PURGE CONTROL VALVE <Turbo> NZSIBCCJ
INSPECTION
(1) Remove the purge control valve.
(2) Connect a hand vacuum pump to, the vacuum nipple of the
purge control valve.
(3) Apply a vacuum of 400 mmHg (15.7 in.Hg.) and check
airtightness.
(4) Blow in air lightly from the canister side nipple and check
conditions as follows.
Hand vacuum pump vacuum Normal condition
0 mmHg (0 in.Hg.1 Air does not blow through

(No vacuum is applied)
I 200 mmHg (8.0 in.Hg.) or more Air blow through I
(5) Connect a hand vacuum pump to the positive pressure

nipple of the purge control valve.
airtightness.
PURGE CQNTROL SOLENOID VALVE NZBIBFH
INSPECTION
NOTE
When disconnecting the vacuum hose, make an identification
mark on it so that it can be reconnected to the original position.
(1) Disconnect the vacuum hoses (non stripe and red stripe
hose) from the solenoid valve
(2) Disconnect the harness connector from solenoid valve.
(3) Connect a hand vacuum pump to the nipple to which the
red-striped vacuum hose was connected.
(4) Apply a vacuum and check for air-tightness when voltage

applied directly to the purge control solenoid valve and
when the voltage is discontinued.
Battery voltage Result 1

Non-Turbo When applied Vacuum leaks
When discontinued Vacuum is maintained
Turbo When applied Vacuum is maintained

When discontinued Vacuum leaks
ECl51C
(5) Measure the resistance between the terminals of the

solenoid valve.
Standard value: 36-44 Q [at 20°C (68OF)] _
6EM137
AIR FLOW SENSOR, ENGINE COOLANT TEMPER-

ATURE SENSOR AND INTAKE AIR TEMPERA-
TURE SENSOR
To inspect these parts, refer to GROUP 14-MPI System
Components. ‘.
AIR CONDITIONER SWITCH

To inspect the air conditioner switch, refer to GROUP 24’--Air
Conditioner Switch.
OVERFILL LIMITER (TWO-WAY VALVE) N2BlBE&
To inspect the overfill limiter (two-way valve), refer to GROUP

14-Fuel Tank.
CANISTER NzslBm
To inspect the canister, refer to GROUP 14-Fuel Line and
Vapor Line.
FUEL FILLER CAP INSPECTION NZSIBJA

Check the gasket of the fuel filler cap, and, the filler cap itself,
for damage or deformation; replace the cap if necessary.
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System 25-l 5
EXHAUST GAS RECIRCULATION (EGR) SYSTEM N2!5lC-
2, COMPONENTS LOCATION
Name Symbol
EGR control solenoid valve <California> C
EGR temperature sensor <California> B
EGR valve <California> A
EGR control
solenoid valve
25-l 6 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EOR) SWem
B
4
\ \
‘\
16A0803
Name 1 Svmbol
I
EGR control solenoid valve <California> D
EGR temperature sensor <Callfornla>
Therm0 valve <Federal and Canada> A

I
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) Svstem 254 7
EGR SYSTEM INSPECTION <Federal and

Canada-2.0L DOHC Engine> N25lCJMa
(1) Disconnect the vacuum hose (green stripe) from the
throttle body, and connect a hand vacuum pump to the
vacuum hose.
(2) Plug the nipple from which the vacuum hose is discon-
nected.
When Engine is Cold-
engine coolant temperature 40°C (104°F) or below

condition
I Idling Try awMng

vacuum
Vacuum leaks
I
When Engine is Hot-

engine coolant temperature 80°C (176°F) or higher

condition

(1.8 in.Hg.1
Changes from 215 mmHg Vacuum is maintained

idling to slightly (8.5 in.Hg.1
unstable
EGR SYSTEM INSPECTION <California> N25lCJN

(1) Disconnect the vacuum hose (green-striped) from the EGR
valve, and connect the hand vacuum pump through the
three-way terminal.
(2) Regarding cold condition [coolant temperature: 20°C (68°F)
or less] and warm condition [coolant temperature: 70°C
(68°F) or more] of the engine, check the following two
points:
<Cold condition of engine>
Engine operation Normal state

Race the engine by The negative pressure does
rapidly press in the not vary.
accelerator pedal. (Atmospheric pressure)
<Warm condition of engine>
Engine operation Normal state
Race the engine by The negative pressure rises

rapidly press in the to 100 mmHg (3.9 in.Hg.1 or
accelerator pedal. more.
(3) Disconnect the three-way terminal, and connect the hand

vacuum pump to the EGR valve.
(4) When a negative pressure of 215 mmHg (8.5 in.Hg.) is
applied during idling, check that the engine stops or idles
unstably.
25-18 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGRI System
EGR VALVE <Except Federal and

Canada-l .8L Engine> N25lCKI
INSPECTION
(1) Remove the EGR valve and check it for sticking, deposit of
carbon, etc.
If such condition exists, clean with adequate solvent to
ensure tight valve seat contact.
(2) Connect a hand vacuum pump to the EGR valve.
air-tightness.
(4) Blow in air from one passage of the EGR to check condition
as follows.
I Applying vacuum I Result I

I 45 mmHg (1.8 in.Hg.1 or less 1 Air does not blow through 1
215 mmHg (8.5 in.Hg.1 or more Air blows through
INSTALLATION
Install a new gasket and EGR valve, tighten bolts to specified
torque.
Specified tightening torque:
< 1.8L Engine> lo-15 N m (7.2-10 ft.lbs.)
<2.0L DOHC Engine> 15-22 Nm (lo-155 ft.lbs.)
THERM0 VALVE <Federal and Canada-

2.0L DOHC Engine> NZHCNGb
INSPECTION
(1) Disconnect the vacuum hoses from the therm0 valve, and
connect a hand vacuum pump to nipple of the therm0
valve.
(2) Apply a vacuum and check the air passage through the
therm0 valve.
REMOVAL
(1) When removing the therm0 valve, do not use wrenches or
other tools on the resin part.
(2) When disconnecting the vacuum hoses, put a mark on the
hose so that it may be reconnected at original position.
INSTALLATION
(1) Apply specified sealant to the threads of therm0 valve and
tighten to specified torque. When installing the therm0
valve, do not use wrenches or other tools on the resin part.
Specified sealant:
MOPAR Part No.4318034 or equivalent
Specified torque: 20-40 Nm (15-30 ftlbs.)
(2) Reconnect the vacuum hoses in position.
‘I
\\
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) Svstem 25-19
EGR TEMPERATURE SENSOR <California> NHCZB
INSPECTION
(1) Remove the EGR temperature sensor.
(2) Place the EGR temperature ‘sensor in water, .and then
measure the resistance value between terminals 1 %%’ 2’
while increasing the water’s temperature.
Replace the EGR temperature sensor if there is a signifi-
cant deviation from the standard value.
7EM0043 I Temperature “C (“F) I Resistance kS2 I

I 50 (122) 160-83 I
I 100~~(212) 11-14 I
INSTALLATION
Install the EGR temperature sensor tighten to specified torque.
Specified tightening torque: lo-12 Nm (7.3-8.6 ft.lbs.)
EGR CONTROL SOLENOID VALVE <Californ&<

INSPECTION
NOTE
When disconnecting the vacuum hose, make an identification
mark on it so‘that it can be reconnected to the original position.
(1) Disconnect the vacuum hose (yellow and green stripe)
from the solenoid valve.
(2) Disconnect the harness connector.
(3) Connect a hand vacuum pump to the nipple to which the
green-striped vacuum hose was connected.
(4) Apply a vacuum and check for air-tightness when voltage

applied directly to the EGR control solenoid valve and when
the voltage is discontinued.
I Battery voltage I Result I

..
I When applied I Vacuum is maintained. I
When discontinued Vacuum leaks.
I
6EM0187
Exhaust Gas Recirculation (EGR) System/
25-20 EMISSION CONTROL SYSTEMS - ‘catalytic Converter
(5) Measure the resistance between the terminals of- the<

solenoid valve.
Standard value: 36-44 Q [at 20°C (68OF)l
6EM0188
AIR-FUEL RATIO CONTROL (MPI) SYSTEM &CAD
l To inspect the air-fuel ratio control (MPI) system, refer to

GROUP 14 FUEL SYSTEM-Service Adjustment Proce-
dures.
l For detailed information concerning the illumination pattern
of the malfunction-indicator light and other aspects of the
self-diagnosis function, refer to GROUP 14 FUEL
SYSTEM-Self Diagnosis.
CATALYTIC CONVERTER N25lCBHa
INSPECTION.
Inspect for damage, cracking or deterioration. Replace if faulty.
Caution
1. Operation of any type, including idjing, should be
avoided if engine misfiring occurs. Under this condition
the exhaust system will operate at abnormally ‘high
temperature, which may cause damage to the”Catalyst
or underbody parts of the vehicle.
2. Alteration or deterioration of ignition or fuel system, or
any type of operating condition which results in enghte
misfiring must be corrected to avoid overheating the
catalytic converters.
3. Proper maintenance and tune up according to manu-
facturer’s specifications should be made to correct the
conditions as soon as possible.

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BACKUP G R O U P I N D E X &ma

;r Service Manual Introduction and

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..‘....................

Intake and Exhaust . . . . . . ..L....................

Please See README.N or README.HTML for additional information

CHRYSLER Emission Contr6l Systems ..............

0 1990 Mitsubishi Motors Corporation Printed in U.S.A.

HOW TO USE THIS MANUAL NOaM

Indicates the incidental operation to be

Limit : 0.15 mm (4059 in.)

This number corresponds to

EXPLANATION OF THE TROUBLESHOOTING GUIDE

scription of cir- l1 tions only as

N o 1 2 T h e ou,s,de-a,, sensor ,nput slgnal IS h e l d to 15°C 159°F)

Terminal CO”dl,,O”* Terminal voltage Provides hints

cedures are fol-

the Indicates the specification to

EXPLANATION OF CIRCUIT DIAGRAMS

The input/output (dire%%

VEHICLE IDENTIFICATION Nmx-

VEHICLE IDENTIFICATION CODE CHART PLA.4

Vehicle Price *Check Model Serial

VEHICLE IDENTIFICATION NUMBER LIST NOOCC--

V.I.N. (except sequence number) Brand Engine Displacement Models Code

4E3CS44ROM E Eap$DTrlon 2.0 liter (122 cu.in.) D22AMNHML4EIRHML4E

VEHICLES FOR CALIFORNIA

V.I.N. (except sequence number) Brand Engine Displacement Models Code

4P3CS34aME Plymouth Laser 1.8 liter (107 cu.in.) D21AMNJELSP/RJELSP

4P3CS44RmME 2.0 liter (122 cuin.) D22AMNHMLSP/RHMLSP

4P3CS44UOME 2.0 liter (122 cu.in.1 D22AMNHFLSP/RHFLSP

4E3CS54UOME 2.0 liter (122 cu.in.1 D22AMNPFLSElRPFLSE

VEHICLES FOR CANADA

V.I.N. (except sequence number) Brand Engine Displacement Models Code 1’ 1

VEHICLE INFORMATION CODE PLATE NOOCD-

Vehicle information code plate is riveted onto the bulkhead in ri

1. MODEL D22AMN HML4P

VEHICLE SAFETY CERTIFICATION LABEL NOOCF-

1. The vehicle safety certification label is attached to the face

2. This label indicates the month and year of manufacture, ;e

ENGINE MODEL STAMPING NOOCG-

1. The engine model number is stamped at the front side on

Engine model Engine displacement

2. The engine serial number is stamped near the engine

Engine serial number Number cycling ‘-w

AA0201 t o w9999 AA0201 - - - - - - - -*AA99997

Theft protection label THEFT PROTECTION NowlAB

For replacement parts

Cautions regarding panel repairs

Transaxle Manual transaxle Automatic transaxle

The illustration indicates left hand side, outer. 3lA0259

: for original equipment parts

The illustration indicates left hand side, outer.

Hood The label is attached at the

Tailgate The label is attached at the

m : for original equipment parts

PRECAUTIONS BEFORE SERVICE wxww

REMOVAL AND DISASSEMBLY

If punch marks or mating marks are made to avoid error in

SERVICING ELECTRICAL SYSTEM

2. If any section of a wiring harness contacts the edge of a

Correct 3. When disconnecting a connector, be sure to pull only the

4. Disconnect connectors which have catches by pressing in

5. Connect connectors which have catches by inserting the